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César BonnínSAP Iberia
™
Herramientas Avanzadas para laGestión de Mantenimiento
Barcelona, 29 de abril de 2009
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 2
Implementation &Integration Service
Integrated SoftwareApplications
StrategicPartners
RCMO / APMConsulting &
Education
Meridium – Partner Estratégico de SAP
Founded 1993
Global presenceAmericas
Roanoke, Virginia, USA – Corp HQHouston, Texas, USASao Paulo, BrazilBlacksburg, VA, USA (Virginia Tech)
EuropeWalldorf, Germany
Middle East/North AfricaDubai, UAE
Asia-Pacific/South AfricaPerth, AustraliaBangkok, ThailandPune, IndiaJohannesburg, South Africa
Our focusHelp customers achieve predictableproduction at the lowest sustainable cost
Serving asset-intensive industries880+ licensed locations70+ countries
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 3
1996 – First joint customers
2000 – Certified integration between SAP PM & Meridium APM
2002 – Synchronization of SAP Master Data in Meridium APM
2003 – BAPI based interface APM <-> SAP
• Oil and Gas• Forest and Paper• Chemicals
• Utilities• Mining
2004 – RCMO product concept and design
2005 – RCMO product co-development
2006 – RCMO™ product release and xApps Certification
2007 – RCMO™ becomes SAP Endorsed Business Solution
2007 – Meridium joined the SAP Industry Value Network for
Relación SAP / Meridium
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 4
RCMO forma parte del Roadmap de SAP
Utilities
Oil & Gas
Chemicals
Mining
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 5
Algunos Clientes conjuntos de SAP y Meridium
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 6
RCMO Live Customers (Excerpt)
Power Generation Canada
Mining Australia
Aluminum Smelter Australia
Paper Netherlands
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 7
RCMO New Customers in 2007/2008 (Excerpt)
Power Generation USA, GlobalTransmission & Distribution
Water Utility USA
Paper Finland, Global
Mining South Africa
Energy, Oil & Gas Canada
Oil & Gas Abu Dhabi
Power Generation Spain
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 8
Meridium – Customer Successes
Meridium RCMO™ is a new RCM solutionbuilt with the latest SAP technology andtightly integrated with SAP EnterpriseAsset Management. RCMO...
- greatly simplifies the process ofimplementing RCM recommendations in SAP
- makes it easy to measure performance andadjust strategies over time
- provides the framework for you to definemaintenance strategies based upon RCM andFailure Modes and Effects Analysis (FMEA)principles
- integrates the recommendations from anRCM analysis into SAP Maintenance Plans inSAP
- drives automated re-evaluation ofmaintenance strategies to ensureeffectiveness is constantly measured forcontinuous improvement
Meridium RCMO™ is a new RCM solutionbuilt with the latest SAP technology andtightly integrated with SAP EnterpriseAsset Management. RCMO...
- greatly simplifies the process ofimplementing RCM recommendations in SAP
- makes it easy to measure performance andadjust strategies over time
- provides the framework for you to definemaintenance strategies based upon RCM andFailure Modes and Effects Analysis (FMEA)principles
- integrates the recommendations from anRCM analysis into SAP Maintenance Plans inSAP
- drives automated re-evaluation ofmaintenance strategies to ensureeffectiveness is constantly measured forcontinuous improvement
"Queensland Alumina has chosen RCMO for ourreliability centered maintenance initiative largelydue to the integration of the product with ourexisting SAP system. QAL believes that an effectiveRCM program will contribute to optimizingequipment performance, help control risk, andassist in improving the reliability of our productionassets.”
Colin McDonald,Maintenance Services Manager
“Ramp-up went much more smoothly than wecould have hoped for. Our IT Project Manager saidthis was one of the best enterprise softwareinstallations she had seen. Our staff work in SAPevery day and with RCMO ‘bolted-on’ and widelyavailable, we can drive the RCM methodology andculture harder and deeper into our organization.”
Richard Brittin, ManagerReliability and Performance
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 9
PROJECT OBJECTIVESCommon maintenance strategies fleet wide
Understanding critical assets and overall risk
Optimize O&M costs
Increased plant reliability and availability
TransAlta: Canadian Utilityconsisting of:• 8,444 megawatts (MW) of
capacity and an additional540 MW underdevelopment.
• 49 facilities in fourregions:Canada; the U.S.;Mexico; Australia
WHY RCMO WAS SELECTEDIntegration to existing portal for fleet wide accessibility
Repository for all analyses to leverage across sites
Integration with SAP EAM and BW
Ability to do RCM and FMEA in one system
KEY CHALLENGESRCM done at 2 facilities in point solutions
Program localized, no sharing of information
No common methodology for RCM
TransAlta, Canada
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 10
Application InstallationDev ->Test->Production migration over several weeks due to larger SAPmigration plansIntegrated into existing TransAlta Portal for fleet-wide accessibilityProvided tool to allow engineers to build systems of technical objects veryquickly with Excel plug-inNo migration of existing analyses during ramp-up
RCMO User TrainingIntroduction to RCM (1day)Product Training (1 day)
Total Implementation Calendar TimeApproximately 8 weeks (4 weeks on-site)Part of larger migration path and followed TA process
TransAlta RCMO Implementation Plan
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 11
“Ramp-up went much more smoothly than we couldhave hoped for. Our IT Project Manager said this wasone of the best enterprise software installations shehad seen, either production or ramp-up.
The Meridium team made commitments to deliver ascope of work by a certain date and met thatcommitment.”
Richard Brittin -Manager of Reliability &Performance
“…Our staff work in SAP every day and with RCMO“bolted-on” and widely available, we can drive theRCM methodology and culture harder and deeper intoour organization.”
TransAlta, Canada
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 12
PROJECT OBJECTIVESAbility to streamline analysis implementation
Maintain justification for maintenance activity
Compare existing asset budget to budget from RCM
Implement a “living” RCM program
QAL – Australian aluminarefiner:
• Largest alumina refineryin the world
• Use the Bayer process –very corrosive forequipment WHY RCMO WAS SELECTED
SAP integrated approach to creating equipment care plans
Able to reclaim and load existing analyses
Multiple methodologies in one system
Reporting on analysis progress and strategy performance
KEY CHALLENGESHad tried several RCM methodologies in the past
Result was 611 studies and 32,000 recommendations
These were never implemented into SAP EAM
Queensland Alumina Limited, Australia
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 13
“QAL believes that an effective RCM program will contributeto optimizing equipment performance, help control risk, andassist in improving the reliability of our production assets…in essence, to stay in control and to modify strategies wherethere is a gap in performance.“
Colin McDonald,Maintenance ServicesManager
“Queensland Alumina has chosen RCMO for our reliabilitycentered maintenance initiative largely due to the integrationof the product with our existing SAP system”
Queensland Alumina Limited, Australia
Introducción a RCM
Visión General de RCMO™
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 15
¡La Fiabilidad impactadirectamente en todo lo
anterior!
¡La Fiabilidad impactadirectamente en todo lo
anterior!
Motivaciones Habituales para RCM/FMEA
Proteger a las Personas y al MedioAmbiente
Reducir Costes año tras año
Aumentar los Márgenes
Consumir menos Energía
Eliminación de Pérdidas
Alcanzar las metas de Producción
Mantener la calidad del Producto
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 16
Rel
iabi
lity
Low High
Maintenance effortDirect / indirect cost
Low
Hig
h
ReactiveMaintenance
PreventiveMaintenance
Condition basedMaintenance
Risk BasedMaintenance
ReliabilityCentered
Maintenance
traditional
innovative
time
Historia de algunos Conceptos de Mantenimiento
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 17
OptimumEffectiveness
Reliability
Tota
l Cos
ts
Cost of UnreliableProduction
Total Cost ofImproved Reliability
Profit gainedfrom improved availability
“Low Hanging Fruit”
Cost to ImproveReliability
OptimumEffectiveness
Reliability
Tota
l Cos
ts
Cost of UnreliableProduction
Total Cost ofImproved Reliability
Profit gainedfrom improved availability
“Low Hanging Fruit”
Cost to ImproveReliability
Equilibrio entre Coste y Fiabilidad
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 18
Typical Overall Impact:1 – 15% Of
Maintenance Costs
Reduce regulatory penaltiesReduce catastrophic failures and save livesManage risk of overall asset operations
Increase production by limiting downtimeIncrease capacity with limited investmentFocus on critical production assets and equipment
YIELD & PRODUCTION
Increase productive life of assetsReduce failure rates and frequenciesIdentify which OEM’s provide most the reliable equipment
ASSET LIFE
Implement and monitor the right maintenancestrategiesImplement proper monitoring proceduresProvide feedback to engineering for increasedreliability
EFFECTIVE &EFFICIENT
COSTREDUCTION
Reduce maintenance costs (labor & materials)Reduce scrap and reworkReduce maintenance backlogIncrease quality
RISK, REGULATORY& SAFETY
Del Mantenimiento Reactivo a una OrganizaciónBasada en la Fiabilidad: Beneficios
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 19
¿Qué es RCM?
“Reliability CenteredMaintenance es un métodoformal para determinar losrequerimientos en cuantoa mantenimiento de unactivo en su contextooperativo.”
“Reliability CenteredMaintenance es un métodoformal para determinar losrequerimientos en cuantoa mantenimiento de unactivo en su contextooperativo.”
“RCM hace énfasis en unaaproximación proactiva almantenimiento. Intenta equilibrarlas mejores prácticas demantenimiento para mitigar unfallo potencial con la importanciade prevenir ese fallo.”
“RCM hace énfasis en unaaproximación proactiva almantenimiento. Intenta equilibrarlas mejores prácticas demantenimiento para mitigar unfallo potencial con la importanciade prevenir ese fallo.”
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 20
El Mantenimiento Centrado en la Fiabilidad (RCM) es una metodologíaprobada para desarrollar estrategias de mantenimiento efectivas
El RCM se aplicó por primera vez comercialmenteen los años sesenta en la industria aeronáutica
Como resultado, los aviones que utilizamoshoy en día son cien veces más fiables
La tasa de accidentes por millón de despeguesse redujo de 6 a 0,02
Actualmente se utiliza prácticamente en todos los sectores que hacen un usointensivo de activos
Durante décadas, los fabricantes han utilizado el RCM para:Mejorar la fiabilidad operativaOptimizar el rendimiento del equipoTomar mejores decisiones en cuanto a diseño y ciclos de vidaControl de riesgo
Breve Historia del RCM
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 21
Accepted Thinking…Manufacturers recommendations are adequate for
formulating failure management policies
The Reality…Generic maintenancepolicies often force
over-maintenance andare not the most
efficient way to manageequipment failures
Main PumpMain Pump
Main Pump
StandbyPump
Main Pump
StandbyPump
Contexto Operativo
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 22
Estrategia de Mantenimiento: ¿Buscar elmomento adecuado?
Time
Probabilityof
Failure
Scheduled PMActivity
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 23
1
2
14%
68%
11% age-related4%2%5%
89% NOT age-related
7%
La realidad del Fallo (Industria Aeronáutica)
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 24
59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95
5
10
15
20
25
30
Accid
ents
per
milli
on ta
keof
fs
Year C.A. Shifrin; Safety in the Civil Aviation Industry, from “Aviation Safety Takes CenterStage Worldwide”, Aviation Week & Space Technology: Vol. 145 No. 19, pp. 46-48
Non-US Operators
US Operators
Registro de Seguridad de la Aviación…¿Qué ocurrió al aplicar los principios del RCM?
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 25
BeforeBeforeRCMRCM
• Impacts production• May have safety orenvironmentalconsequences
DefectsDefectsUnplannedUnplannedHigh costsHigh costs
• Reduces risk• Generally non-intrusive
Failure FindingFailure FindingTasksTasks
• Generally non-intrusive• If it’s working leave italone
ConditionConditionMonitoringMonitoring
•Intrusive•Impacts production•Often introduces defects
ScheduledScheduledRestoration &Restoration &Discard TasksDiscard Tasks
DefectsDefects
ScheduledScheduledRestoration &Restoration &Discard TasksDiscard Tasks
ConditionConditionMonitoringMonitoring
Failure FindingFailure FindingTasksTasks
RCM
Beneficios de la Implementación de RCM
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 26
Las 7+1 Preguntas de RCM
1. ¿Cuáles son las funciones y los estándares derendimiento deseados para el activo en sucontexto operativo?
2. ¿Cuáles son los fallos que hacen que elequipo deje de cumplir sus funciones?
3. ¿Qué causa cada fallo funcional?4. ¿Qué pasa cuando ocurre un fallo?5. ¿Qué consecuencias tiene el fallo?6. ¿Qué puede hacerse para predecir o prevenir
el fallo?7. ¿Qué puede hacerse si el fallo no puede
predecirse o prevenirse?
¿Qué activos o sistemas quiero analizar?
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 27
1. What are the desired functions and performance standards? FunctionsTo fill a tank at a minimum rate of 100 gal. per min
2. In what ways can it fail to fulfil its functions? Functional FailureTank fills at a rate of less than 100 gal. per min
3. What causes each functional failure? Failure ModesFilter clogs due to debris
4. What happens when each failure occurs? EffectsFlow rate is restricted until pump can no longer meet process demand
5. In what way does each failure matter? ConsequencesProduction impacted, line must be taken down to repair, 1 hr of downtime
6. What can be done to predict or prevent each failure? TaskMonitor flow with SAP MII, alert when flow is impacted.
7. What can be done if the failure cannot be predicted or prevented? RedesignBuild valve and piping to redirect flow ahead of filter
RCM
FMEA
Las 7+1 Preguntas de RCM
¿Qué activos o sistemas quiero analizar?
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 28
FunctionalAnalysis
CriticalityAssessment
Criticality
ReliabilityCentered
Maintenance
Failure Modesand Effects
Analysis
StructuredReview
MaintenanceStrategy
Implement Strategy in SAP Collect WorkHistory
High Medium Low
Evaluate Strategyand Optimize
Método de Desarrollo de una Estrategia deMantenimiento
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 29
1. Tareas de mantenimientopreventivo
2. Tareas de supervisión einspección
3. Otras recomendaciones como:Procedimientos operativos
Optimización de recambios yherramientas
Formación
Rediseños
Resultados Típicos del Proceso RCM
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 30
Operaciones con SAP EAM/PM/PS
SAP
Órdenes
Pb.: Los costes demantenimientoaumentan si laestrategia utilizada noreduce lasindisponibilidades noplanificadas.Responsable
Mantenimiento
Resp.Fabricación
Pb.: GMAO permite unagestión eficiente de laejecución de tareas demantenimiento, perofalta eficacia. No sesabe si se está haciendoel trabajo adecuado enel momento justo y en elactivo adecuado.
Hay un continuo ir y venir deactividad de mantenimiento,pero sin progreso real.
Pb.: ¿Cuál es mi mejorestrategia demantenimiento?Una pobre fiabilidad delos equipos lleva aparadas no planificadasy menor disponibilidad.
Pb.: ¿Qué activos representanlos mayores riesgos en cuantoa seguridad, conformidad ymedioambiente? ¿Cuáles sonlas mejores prácticas?
¿Qué reporta el gasto enmantenimiento? Laproducción y laactividad no mejoran.
“Buena Gestión pero sin Progresos”Sin progresos en fiabilidad y coste a pesar de procesos eficientes
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 31
ResponsibleMantenimiento
Resp.Fabricación
Cómo deberían ser las operaciones
SAP
Órdenes
En un mundo perfecto...
1. Estrategia: Identificary gestionar los sistemasy activos críticos através de un gestión a lavez eficiente y eficaz
4. Estrategia: Definir e implementarestrategias basadas en mejoresprácticas en toda la cartera de activosempresariales
2. Estrategia:Implementar lasestrategias correctas ymonitorizar de cerca losactivos para minimizarlas paradas noplanificadas,incrementar laproducción y controlarlos costes demantenimiento
3. Estrategia: Actualizacióncontinua de las estrategiasde mantenimiento paraminimizar las paradas noplanificadas, incrementar laproducción, controlarcostes, mitigar riesgos, … ymedir los resultados
Si pudiéramos…..
Las operaciones de Mantenimiento deberían seguirEstrategias para mejorar la Eficacia del gasto
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 32
ResponsibleMantenimiento
Operaciones con SAP y RCMO
RCMO
SAP
Órdenes
1. Resultado: RCMOIdentifica los sistemas yactivos críticos ygestiona sus riesgospermitiendo a la vezeficiencia y eficacia enla gestión de activos
¡Esto ya me gustamás!
2. Solución: RCMO crealas estrategiascorrectas e identificacómo monitorizar decerca los activos paraminimizar las paradasno planificadas,incrementar laproducción y controlarlos costes.
3. Solución: RCMOanaliza de formacontinua lasestrategias y evalúalos métodos parareducir las paradas,mitigar los riesgosde producción,seguridad ymediambiente,… ymedir los resultados,incluidos los costes.
¡La producción estámejorando de forma
espectacular!
4. Solución: RCMO crea y documenta mejoresprácticas para su implementación en toda lacartera de activos empresariales
RCMO by Meridium Facilita la Mejora de la Eficacia delGasto de Mantenimiento a través de Estrategias
Resp.Fabricación
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 33
El enfoque de SAP EAM es en la ejecución eficiente de:Planificación y Programación de MantenimientoTrabajo de MantenimientoGestión de RepuestosHistorial de Mantenimiento y Reportes
RCM se enfoca en la eficacia, y contesta la pregunta…
¿Cómo sabe si está
haciendo el mantenimiento correcto?
¿Por qué utilizar RCM con SAP EAM?
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 34
Buen mantenimientoBuen mantenimientobien ejecutadobien ejecutado
Buen mantenimientoBuen mantenimientomal ejecutadomal ejecutado
Mal mantenimientomal ejecutado
Mejores EstrategiasMejores Estrategiasde Mantenimientode Mantenimiento
Mejores PlanificaciMejores Planificacióónn yyEjecuciEjecucióónn deldel MantenimientoMantenimiento
Mal mantenimientoMal mantenimientobien ejecutadobien ejecutado
Instalaciones/activos con
el mejor rendimiento
SAP EAM + RCMO de Meridium
El mejor resultado
Ejecución Eficiente + Estrategia =Optimización
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 35
EvaluaciónRendimiento
de la Estrategia
AplicarMetodología Apropiada
Identificar ActivosCríticos y Modos
de Fallo
RCM FMEA
Evaluar Riesgo Actualizar TareasÓptimas de
Mantenimientoy Monitorización
Finalización/Histórico
de Trabajos
SAP EAM
Ejecución
Planificación/Programación
ExistingStrategy
Identificaciónde los Trabajos
Reporting/Análisisde la Eficiencia
del Proceso
Implementaciónde la Estrategia
¿Somos eficaces? ¿Somos eficientes?
Cómo RCMO by Meridium con SAP EAM permiteuna Gestión de Activos Eficiente y Eficaz
Introducción a RCM
Visión General de RCMO™
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 37
Implementing Asset Management Programsin iterations from core to advanced...*)
ENTERPRISE LEARNING
MOBILEASSET MGT
SCHEDULING & RESOURCEOPTIMIZATION
Field Service Management
Asset Knowledge Management
FINANCIALS
Enterprise Management & Support
ENGINEERING &CONSTRUCTION
Core Asset Management
GIS OMS PLANT MGT
Operations Integration
Asset Management Data and Process Platform
Plat
form
Adva
nced
Fun
ctio
ns &
Pro
cess
es
Core
Ent
epris
eAs
set M
anag
emen
t Fun
ctio
ns &
Pro
cess
es
OperationalRisk Mgt
Advanced Maintenance
Program sophistication andinnovation needs accurateand meaningful core data!
RISK-BASEDMAINTENANCE
COLLABORATION
STRATEGICENTERPRISE MGT
DMS EMSSCADA
ANALYTICS
REAL ESTATEMGT
EH&S
INDIRECTPROCUREMENT
PROJECT &PORTFOLIO MGT
QUALITYMGT
MAINTENANCE &OPERATIONS
DECOMMISSIONINGCONNECTIONS
MGTWORKFORCE
MGT
INVENTORYMGT
PROCUREMENT SPAREPARTS & SERVICES
METER &DEVICE MGT
HUMAN CAPITALMANAGEMENT
TASK MANAGEMENTENTERPRISE KNOWLEDGE MGT
RCMFMEA RBI
Iterations andre-evaluationsof programs
Sensors
*) Source:SAP IBU UtilitiesDr. Walter Kienle
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 38
100% SAP Technology
Developed with Web Dynpro using J2EE and ABAPCommon logon and security modelRuns natively on SAP Web Application ServerBroad platform & DB supportInherent support for localization
Infrastructure Requirements (RCMO 1.3 and 2.0)SAP ECC version 5.0 or 6.0SAP Web Application Server version 7.0SAP Business Intelligence version 3.5 or 7.0 (optional, recommended)SAP Portals version 7.0 (optional)Windows OSOracle Database, SQL Server Database, MAXDB
Hardware RequirementsNo additional requirements beyond Netweaver ’04 recommendations
Tecnología
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 39
¿Por qué integrar RCMO con SAP EAM?
Después de una revisión con clientes de SAP, éstos indicaron que los tres principalesretos en el proceso de RCM son:
1. Las herramientas RCM están desconectadasEl proceso de carga de las recomendaciones en SAP es manual
Una vez cargadas las recomendaciones, el análisis RCM original se pierde
2. Medir el resultado RCM resulta un proceso largo y difícil
3. Mantener los procesos RCM activos es prácticamente imposible
Many RCM assessments fall short today because therecommendations for making improvements are not translatedinto action-oriented tasks within the production system.
Next Generation Enterprise Asset ManagementPatrick Connaughton, Forrester Research
April 24, 2006
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 40
1. Proceso estructurado para desarrollar estrategias demantenimiento
Reliability Centered Maintenance (RCM)Failure Modes Effects and Criticality Analysis (FMEA/FMECA)
2. Integración con los proceso de trabajo de SAP PMUtiliza los datos maestros de SAPPlanificación y ejecución de MantenimientoAnálisis de la efectividad del Mantenimiento
3. Permite la reevaluación automática de las estrategiasde Mantenimiento para la mejora continua.
RCMO – Funcionalidad Clave
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 41
11 Analyze/IdentifyCritical Assets
DefineSystems/Assets
to Analyze22
ImplementStrategies
(Maintenance,Monitoring and
Inspection)
ConductRCM/FMEA
Analysis
DevelopRecommendations
33
44
55
ContinuallyRe-evaluateStrategies
66
Closed Loop ReliabilityCentered Maintenance
Visión General de la Solución RCMO
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
RCMO
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
StrategyStrategyEvaluationEvaluation
MaintenanceMaintenanceAnalysisAnalysis
EstablishEvaluation
Criteria
OptimizeStrategies
BW
RCMRCM
FMEAFMEA
Risk EvaluationRisk Evaluation
Flujo del Proceso RCMO / SAP
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 43
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 44
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 45
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
RCMO
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
StrategyStrategyEvaluationEvaluation
MaintenanceMaintenanceAnalysisAnalysis
EstablishEvaluation
Criteria
OptimizeStrategies
BW
RCMRCM
FMEAFMEA
Risk EvaluationRisk Evaluation
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 47
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 49
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 50
SAPEAM
MeridiumRCMO
System Definition Standard
CAD, GIS,SCADA,Papier…
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 51
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 58
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
RCMO
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
StrategyStrategyEvaluationEvaluation
MaintenanceMaintenanceAnalysisAnalysis
EstablishEvaluation
Criteria
OptimizeStrategies
BW
RCMRCM
FMEAFMEA
Risk EvaluationRisk Evaluation
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 60
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Analysis
FunctionFunction Failure
Failure ModeFailure Effect
Recommendation / Task
RCM
FMEAFMECA
Estructura Jerárquica de un Análisis
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 66
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 70
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
RCMO
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
StrategyStrategyEvaluationEvaluation
MaintenanceMaintenanceAnalysisAnalysis
EstablishEvaluation
Criteria
OptimizeStrategies
BW
RCMRCM
FMEAFMEA
Risk EvaluationRisk Evaluation
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 72
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 73
Criticality matrix
For each system, each failure mode and each recommendationa Risk Ranking / Criticality can be defined with risk matrix:
9876587654765436543254321
Consequence
Pro
babi
lity
Low High
Hig
h
Lo
w
For example:
Weight: 10
-> Risk ranking = 10*7 = 70
Your risk matrix can be customized (with n lines / m columns, values) andyou define the areas with different weights:
safety environment production image Risk rankingweight: 10 weight: 5 weight: 10 weight: 1
Risk ranking: 30 + 25 + 40 + 6 = 101
98765
87654
76543
65432
54321
Consequence
Prob
abilit
y
Low High
Hig
h
Lo
w
98765
87654
76543
65432
54321
Consequence
Prob
abilit
y
Low High
Hig
h
Lo
w
98765
87654
76543
65432
54321
Consequence
Prob
abilit
y
Low High
Hig
h
Lo
w
98765
87654
76543
65432
54321
Consequence
Prob
abilit
y
Low High
Hig
h
Lo
w
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 74
Example of a Risk Matrix
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 75
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 76
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 81
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
RCMO
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
StrategyStrategyEvaluationEvaluation
MaintenanceMaintenanceAnalysisAnalysis
EstablishEvaluation
Criteria
OptimizeStrategies
BW
RCMRCM
FMEAFMEA
Risk EvaluationRisk Evaluation
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 83
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 84
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 85
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 86
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 91
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 100
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 101
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© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 103
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 104
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 105
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 106
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
RCMO
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
StrategyStrategyEvaluationEvaluation
MaintenanceMaintenanceAnalysisAnalysis
EstablishEvaluation
Criteria
OptimizeStrategies
BW
RCMRCM
FMEAFMEA
Risk EvaluationRisk Evaluation
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 108
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 109
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 110
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 111
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 113
RCMO™ 2.0 Enhancements (01/2009)
Upfront System Definition and System Criticality Analysis
Integration to SAP Document Management System (DMS)
Decision Logic Builder
Revision History
Automatic Node Numbering
Mitigated Risk Ranking for Recommendations
Many Enhancements for Reports,Search capabilities, Importing analyses and numerous others
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 114
¡Muchas Gracias!
César BonnínExperto en Soluciones
SAP Iberia
E-mail: [email protected]
© SAP/Meridium 2009 / SAPIberia, Abril 2009 Page 115
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