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Enterprise Asset Management EAM & ERP Integration MRO & Preventative Maintenance Anand Subramaniam
[object Object],[object Object]
Highlights ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Current Challenges
Industry Challenges Industry Challenges ,[object Object],[object Object],Market Consolidation Ongoing industry consolidation leading to over capacity  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
What keeps “CXO” awake at night Improve Yield Improve Production Rate Increase Machinery Uptime Extend Asset Life Decrease Cost Defer Maintenance Actions Reduce Maintenance Cost Improve Availability Improve working capital Safety Compliance Meeting Delivery Schedules Increase Operating Earnings Reduce Inventory Reduce Asset Base Reduce Time to Market Increase Revenue
Business Challenges ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cause & Effect Operating Loss Categories ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Risk Exposure
Risks Risks Cost of Spares Costs of doing Less or Nothing Cost of Less Product Quality Overhead Costs Costs of Internal & External Labour Cost of Lost Image Costs of Downtime & / or Production Loss Consequences of Failures Potential Failures Reliability & Probability of failures Failure Modes Root Cause Failure Analyses
Business - Drivers, Objectives, Value
Business Drivers ,[object Object],[object Object],Business Drivers ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Governance Improve visibility and control over expenditures Productivity Increase asset productivity and speed up repair cycles Continuous Improvement Drive continuous improvement through Analytics
“CXO” Objectives ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Business Value Business Value ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
EAM - Overview
Asset Management Why? Schedules preventive maintenance to prevent problems  Improves asset performance to  reduce downtime Extends asset life to avoid new  capital purchases Improves processes such as warranty management and streamlines purchasing Tracks equipment according to regulatory guidelines
EAM Definition ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
EAM - Overview ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Enterprise Asset Management System ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Maintenance Management System ,[object Object],[object Object],[object Object],[object Object]
Functionality Overview ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
EAM & ERP Integration
Integration - EAM & ERP Modules EAM Product & Maint WO Transactions Costs Updates WO Updates, Catalogs Purchase Produce Inventory Projects Service Suppliers Asset Depreciation Service Request Linked to  WOR / WO WO Materials, Reqs Linked to WO & Workflow Time & Attendance Receiving Project / Task, WO Costs Accounts Payable General Ledger Accounts Receivable Fixed Assets Facility Management Human Resource Posting Integration Chart of Accounts WO Billing Depreciable Assets Requisition, PO,  Matching & Reconciliation Employees & Skills Maintainable Assets Time Entry Customers
Linkage – EAM, ERP & Other Systems EAM Integration Performance Analytics Roadways & Pipelines Fleet & Transportation IT Assets Building & Facilities Enterprise Resource Planning Manufacturing Drilling & Services Labor Management Bridges IT / GIS Assets Material Management Construction/ Infrastructure Service Request Work Management Preventative Maintenance Maintenance Repair & Overall Purchasing
Asset Performance Process Flow Forecasting Resource Planning Material Request Work Requests Entry Work Order Generation Task Planning Work Scheduling Work Order Update and Close Out Asset Performance Procurement Manufacture Projects Inventory Services Time & Attendance Human Resources General Ledger Fixed Assets Accounts Receivable Facility Management Accounts Payable Suppliers Customers
Deploying Lean / Six Sigma
Quality, Cost, Cycle Time Improvement Sales & Marketing Information Technology Engineering Supply Management Service Finance Sales & Operational Planning Production Waste ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Parts Management
Challenges - Parts Management ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Parts Management - Impact on Business ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Key Success Metrics Factors Preventing Success ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Product Design Supply Chain / Procurement Manufacturing & MRO Sales & Marketing Core Business Process
Maintenance Repairs & Overhaul (MRO)
Maintenance Repairs & Overhaul W arranty  &  Returns Management Spare Parts Management  S ervice Contract Service Notification Service Operation – Planning & Control Service Order Process Manage Contracts MRO
Why MRO is required? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preventative Maintenance
Need for Preventative Maintenance ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Preventative Maintenance Flow Service Contract Cost Work Complete Service Order Progressive Billing Service Plan Maintenance Service PlanSchedule Equipmenet Location Create Service  Order Service Parts Confirm Work Done Defect found? N Y Close Service Order Perform Repairs Create  Notifications for Repair Certificatify Process Service Order  Delivery of Spares Amend Service Order (Date, Priority) Shipment of Spares Perform Service (routine, anual)
Overall Equipment Effectiveness (OEE)
Overall Equipment Effectiveness  ,[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object]
[object Object],[object Object]

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Enterprise Asset Management

  • 1. Enterprise Asset Management EAM & ERP Integration MRO & Preventative Maintenance Anand Subramaniam
  • 2.
  • 3.
  • 5.
  • 6. What keeps “CXO” awake at night Improve Yield Improve Production Rate Increase Machinery Uptime Extend Asset Life Decrease Cost Defer Maintenance Actions Reduce Maintenance Cost Improve Availability Improve working capital Safety Compliance Meeting Delivery Schedules Increase Operating Earnings Reduce Inventory Reduce Asset Base Reduce Time to Market Increase Revenue
  • 7.
  • 8.
  • 10. Risks Risks Cost of Spares Costs of doing Less or Nothing Cost of Less Product Quality Overhead Costs Costs of Internal & External Labour Cost of Lost Image Costs of Downtime & / or Production Loss Consequences of Failures Potential Failures Reliability & Probability of failures Failure Modes Root Cause Failure Analyses
  • 11. Business - Drivers, Objectives, Value
  • 12.
  • 13.
  • 14.
  • 16. Asset Management Why? Schedules preventive maintenance to prevent problems Improves asset performance to reduce downtime Extends asset life to avoid new capital purchases Improves processes such as warranty management and streamlines purchasing Tracks equipment according to regulatory guidelines
  • 17.
  • 18.
  • 19.
  • 20. EAM & ERP Integration
  • 21. Integration - EAM & ERP Modules EAM Product & Maint WO Transactions Costs Updates WO Updates, Catalogs Purchase Produce Inventory Projects Service Suppliers Asset Depreciation Service Request Linked to WOR / WO WO Materials, Reqs Linked to WO & Workflow Time & Attendance Receiving Project / Task, WO Costs Accounts Payable General Ledger Accounts Receivable Fixed Assets Facility Management Human Resource Posting Integration Chart of Accounts WO Billing Depreciable Assets Requisition, PO, Matching & Reconciliation Employees & Skills Maintainable Assets Time Entry Customers
  • 22. Linkage – EAM, ERP & Other Systems EAM Integration Performance Analytics Roadways & Pipelines Fleet & Transportation IT Assets Building & Facilities Enterprise Resource Planning Manufacturing Drilling & Services Labor Management Bridges IT / GIS Assets Material Management Construction/ Infrastructure Service Request Work Management Preventative Maintenance Maintenance Repair & Overall Purchasing
  • 23. Asset Performance Process Flow Forecasting Resource Planning Material Request Work Requests Entry Work Order Generation Task Planning Work Scheduling Work Order Update and Close Out Asset Performance Procurement Manufacture Projects Inventory Services Time & Attendance Human Resources General Ledger Fixed Assets Accounts Receivable Facility Management Accounts Payable Suppliers Customers
  • 24. Deploying Lean / Six Sigma
  • 25.
  • 27.
  • 28.
  • 29. Maintenance Repairs & Overhaul (MRO)
  • 30. Maintenance Repairs & Overhaul W arranty & Returns Management Spare Parts Management S ervice Contract Service Notification Service Operation – Planning & Control Service Order Process Manage Contracts MRO
  • 31.
  • 33.
  • 34. Preventative Maintenance Flow Service Contract Cost Work Complete Service Order Progressive Billing Service Plan Maintenance Service PlanSchedule Equipmenet Location Create Service Order Service Parts Confirm Work Done Defect found? N Y Close Service Order Perform Repairs Create Notifications for Repair Certificatify Process Service Order Delivery of Spares Amend Service Order (Date, Priority) Shipment of Spares Perform Service (routine, anual)
  • 36.
  • 37.
  • 38.