“Customer for life through the delivery of excellence”
Drakenstein’s Maintenance and Asset Management Approach
Bouke Spoelstra February 2013
Drakenstein’s Requirement
• Requirement Definition • Current Asset Register (constant verification and
updating)
• Optimisation of their Operational Resources
• Unified Process of Managing Assets and Work
• Integrate Data Sources: Spatial, SCADA and
Financial
Process Impact on Asset Register
Asset Register
CAPEX
Maintenance
Service Strategy
Condition Assessment
Operations
Financial Accounting
Asset Disposal
Supply Chain
Unified Business Process for all Work
• Drakenstein’s Flow Trough Business Process • Work Initiators:
• Help Desk: Service Request
• CAPEX
• Planned Maintenance
• Unplanned Maintenance
• Work Planning
• Scheduling
• Assigning & Dispatching
• Field Force Management
• Closeout
• Feedback
• Analysis
“Customer for life through the delivery of excellence”
Client Call Create Service
Request Classify Request
Create Work Order
Work Planning
Service Management Process
Helpdesk: Client Calls
Other Feeds: • E-mail • Self Service Application
Location Identification
Filter for correct street or ERF
Search Hierarchies/ Drill down Search Map
Verify duplicate Service Requests
Work Order reference SR for Auto status updates
“Customer for life through the delivery of excellence”
Master Plan Project
Definition Field
Estimating
Office Estimating
Work Package Development
Notifications
Work Planning
CAPEX Process
Functions: • CAPEX Cost Centre • Budgeting • GIS Integration • Compatible Unit Estimator • Standard Job Plans • Standard Project Templates • Supply Chain Integration • Outages Planning • Maximo Scheduler • Customer Notifications • Crew Management • Workflow signoffs
“Customer for life through the delivery of excellence”
Preventive Maintenance
Launching Conditions
Job Plans & Procedures
PM Predictions Notifications
Preventive Maintenance Generation
Work Planning
Preventive Maintenance
Functions: • Meters (SCADA) • Calendar • Standard Job Plans • Master PM’s • PM Sequencing • Supply Chain Integration • Outages Planning • Maximo Scheduler • Customer Notifications • Crew Management • Workflow signoffs
“Customer for life through the delivery of excellence”
Smart Feeds Incident Reporting
Trending Actions Launching
Prioritisation Work Planning
Corrective & Emergency Maintenance
Functions: • DMS Integration • SCADA Integration • Condition Monitoring
• Infrared Cameras • Online Monitoring • High/Low Alarm Levels • High/Low Action Levels • Colour conditions
• GIS Integration • Incident Classification • Work Prioritisation • Standard Work Templates
“Customer for life through the delivery of excellence”
Work Planning Material, Resource Planning
Approve Work
Crew Scheduling
Assignment Dispatching
Field Force Management
Planning to Execution
Functions: • Job Plans • Resource selection
• Material • Labour • Tool • Services
• Planning Tools • Dispatching Tools • Mobility Tools
CAPEX, Preventive Maintenance, Service Requests, Incidents
P&S Optimization Achievement on Productivity
13% Personal
10% Clerical
15% Waiting for Jobs
22% Travel Time and Stores
10% Waiting for Instructions
30% Productive Work
Reduce from 70 % to 50%
50% Productive Work
Before P&S Optimization
60% Increase in Productivity
After P&S Optimization
Planning & Scheduling Optimization ROI
Impact of Improvement
• Reduce time to complete jobs by 33 %
• Increase Productivity (Labor wrench time) by 60 %
Effect Of Improvement
• 3 techs at 30% = 90 % total productivity
• 2 techs at 50% + 1 planner @ 0% = 100% total productivity
• A planner can plan work for 15-40 technicians depending on industry and
complexity of maintenance work. Average ratio is 1-20
• One planner /scheduler for 20 technicians (21 employees) will yield the same
output as 30 technicians without planners
Visual Planner allows Planners, Schedulers and Supervisors
achieving a 20% time saving (One full day per week)
Work Management Focus Areas
Forecast Work
Identify Resource Gaps
Availability: • Assets • Location • Material • Tools
• Labor/Crews
Resource Leveling
Graphical UI
Labor and Crews
Graphical UI
Public Map Control
Route Optimization
Labor and Crews
Assign Emergency Work
Communication
To Field Technicians
Capacity Planning
Schedule Compliance
Resource Optimization
Assignment Dispatching Real-time
Communication
Roles in Managing Work
• Defines and adjusts labor/crew availability along with resource leveling
• Capacity Planning
• Assigns work orders to resources
• Continuously optimizes the schedule as the operational environment changes
• Sequence and route work assignments based on geography
Scheduler/Planner
• Monitor field resources and work order progress and status
• Monitor the location of field resources compared to open orders
• Enter status and complete work orders on behalf of technicians who don't have mobile devices • Sequence and route ongoing work assignments based on geography and optimization
Dispatcher
• Supervisor approves and assigns work on mobile devices
• Receive work orders in the field and provide real time status updates to dispatch
• Complete, edit and approve work orders on mobile devices along with viewing work on a map with optimal driving directions • Notify dispatch of potentially dangerous situations, incomplete work
Field Technician
Scheduling: Resource Load and Availability
19
Planning: Resource Optimisation
Dispatching: Real-time monitoring
Mobile Interface
2 x Clicks
Location
Direction
Speed
Mobile Supported Devices
Service Request feedback
Completing the work order a message will appear notifying you that the Service Request will be Resolved
Prepare for: Meter Management Lifecycle
Truck
(Rolling Storeroom)
StockQuarantined
Meter Shop
Stock
Meter Random
Sample Test
Meter ShopStoreroom or
Staging Area
Stock
Vendor Marriage
and Test Files
Status: Not Ready
Location: Meter
Shop
A
ASN File
Meter
Shipment
Meter Receipt Meter Marriage
Premise
Active
Left in Open
Sync
StoreroomMeter Shop
Needs Test
Truck
(Rolling Storeroom)
Needs TestNeeds Test
Meter Shop
Stock
Meter Inspection/Test
Meter Fails Test,
Lost or Obsolete
Retired
Lost
Obsolete
Meter End of Lifecycle
Storeroom or Metershop
Meter
Passes
Test
Storeroom
Stock
A
Service
Order
Service
Order
Meter
Installation
Meter
RemovalMeter
Shipment
The Value to Drakenstein
• Unified solution for:
• Service Management
• Work Management • Asset Management • Supply Chain Management
• For all asset groups • Infrastructure • Plant • Facilities • Transportation • IT assets
• Visualisation • GIS integration • Map Integration • Dashboards • BI Cognos • Customer WEB UI
Asset Management
Work Management
Supply Chain Management
Service Management
Questions?
IBM Maximo: The Operational Solution
Organisation
Enhanced Workflow in SLAs and Escalation Manager
Configuration – UI, Database Fields, and Applications
Maximo Integration Framework (MIF) – Native Integration Capabilities
KPIs / Reporting / Analysis
Security & Administration
IBM Maximo Detail Functions
Asset Management
Work Management
Materials Management
Purchasing Contract Management
Service Management
•Locations
•Asset
•Failure Codes
•Conditioning
Monitoring
•Meters
•Meter Groups
•Classifications /
Specifications
•Linear Assets
•Maximo Spatial
•Depreciation
•Job Plans
•Routes
•Work Order Tracking
•Failure Reporting
•Safety
•Quick Reporting
•Labor
•Qualifications
•Lock-Out / Tag-Out
•Tools / Crafts /
Companies
•Preventive
Maintenance
•Master PM
•Compatible Unit
Estimating
•Resource Scheduling
• Item Master
•Storerooms
• Inventory
•Lot Management
•Kitting
• Issues & Transfers
•Condition Codes
•Stocked Tools
•Service Items
•Classifications /
Specifications
•Request for Quotation
•Receiving
•Receiving Inspections
•Purchase Requisitions
• Invoices
•Purchase Orders
•Desktop Requisitions
•Purchase Contracts
•Master Contracts
•Warranty Contracts
•Lease / Rental
Contracts
•Labor Rate Contracts
•Payment Schedules
•Service Catalogs
•SLA Management
•Service Requests
• Incidents
•Problems
•Changes
•Releases
•Solutions
•Ticket Templates
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