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STO 101: Leveraging SAP & Prometheus to Plan and Execute STOs Kevin Harp | Account Manager Sean McWhirter | Functional Consultant
STO 101: Leveraging SAP & Prometheus
to Plan and Execute STOs
Kevin Harp | Account ManagerSean McWhirter | Functional Consultant
• Prometheus Overview
• Goals & Challenges when planning shutdowns & turnarounds
• Solution and Expected Benefits
• ERP Advanced + STO Demonstration
• Q & A and Upcoming Event
Agenda
Introduction to Prometheus Group
• What we do: Simplify enterprise asset management software• Extensive expertise: 15+ years of “hands on” experience, across more than 1,200
global implementations• Scope of solutions: Plant maintenance, shutdowns/turnarounds, mobility, analytics• Used by industry leaders: In oil & gas, manufacturing, life sciences, and chemicals• Based in Raleigh, North Carolina: With a global presence
What Makes Us Unique?
Improved Bottom LineIncrease efficiency and data
integrity to save money
Customer ServiceGet the answers you need
when you need them
Built within SAPSAP Certified with no middleware required
Rapid ImplementationUp and running in as little as
three weeks
User-friendly Interface
User-Friendly Interface
Improve SAP usability and Increase end-user adoption
Real-Time DataMake decisions based on
most up to date information
Who Uses Prometheus?
INDUSTRIESOil & Gas
Chemicals
Utilities
Food & Beverage Asset Intensive Manufacturers
Life Sciences
Top 6 oil companies Top 3 paper companies 4 of the top 5 mining
companies 6 of the top 10 chemical
companies
Outcomes/Benefits
ReactiveWork OrdersLess than 20%
Average Savings Per Site
20%• Scheduling Conflicts• Downtime• Risk• Cost
• Visibility• Compliance• Asset Utilization• Wrench Time• Production Yield• Effective Capital Spending
or greater in maintenance costs
STOs are not stand-alone events, but are high-cost, high-impact events, which represent the execution of
the company strategy over a period of many years.
How Are STOs different?
• STOs are “Whole Business Events”, not simple function-specific events
• Typically executed under strict time constraints with severe financial impacts for project delays
• Significant changes in scope during outage periods, resulting from discovery work.
STOs Require Multi-Phase Approach • Defining/Scoping• Preparation• Execution• Startup/Turnover• Evaluation
Shutdowns, Turnarounds, and Outages (STOs) are sizable events that are executed under strict time constraints with severe financial impacts for project delays.
Poorly executed STOs can cost an organization:• Millions of dollars in lost revenue• Increase operating cost
Business Challenges of Shutdowns, Turnarounds, and Outages:• Workforce Safety: Ensuring workforce safety of all parties involved in STO• Scope Creep: Managing and prioritizing emerging work to avoid “Work Cuts” and to stay within project plan,
time-line and budget• Workforce Management: Resource capacities typically triple during turnaround projects (3rd Party
Contractors/Vendors)• Process and Procedures: All stakeholders have a clear understanding of specific STO process and know how
to properly channel unique information• Progress Tracking: Having the right STO management system/tools to properly manage Work Progress, Cost
Activities, and Safety Reports • Real-Time Data: Access to real-time STO budget performance to make more informed decisions on course of
action
Challenges
Plan for the unexpected • Regardless of how detailed your project plan is, ‘found’ or ‘discovery’ work is inevitable.
Establish clear goals with contractors • When working with contractors, communicate your specific expectations.
Don’t underestimate the importance of a solid cleaning plan • When cleaning time is underestimated, all subsequent work backs up because other trades
cannot gain access to complete their assigned tasks.
Keep track of ordering tools and equipment • A turnaround can be stopped cold if basic supplies are not accounted for. To avoid chaos, don’t
assume that simple resources will be available at turnaround time.
Goals & Best Practices
Solution | Prometheus ERP Advanced
• Out-of-the-box applications that work within your current ERP system (SAP)• Integrated suite of products to evolve your plant maintenance strategies• Real results: reduced downtime, increased rate of production, cost-savings
Customizing Your Solution for STOs
+ STO is an add-on to Prometheus ERP Advanced
+ STO
+ STO Features
Auto Leveler Percent % CompleteSimulation Mode
Planned vs. Base vs. Actual Capacity Utilization Planned vs. Actual Cost
Product Demonstration
Prometheus +STO
Availability• Reduces downtime with better planning & scheduling work flow execution• Synchronizes maintenance work with equipment availability• Improves capacity planning• Views the material availability for all components of a project or WBS
Cost• Improves maintenance time on equipment with the ability to level work and resources• Reduces overtime and outsourced labor• Improves planner and scheduler efficiency – do more at same resource level• Improves the ability to level work and resources• Provides real-time visibility to proactively monitor budget and timelines to reduce project overruns• Eliminates the need for additional servers or integration software
Risk and Compliance• Allows for “what-if” analysis without interrupting projects• Determines critical path of all project activities• Instills a common system of record (data inside SAP)• Preserves institutional knowledge and knowledge transfer during worker transition• Reduces backlog with work completed as planned• Instills a common system of record (data inside SAP)• Preserves institutional knowledge and knowledge transfer during worker transition• Supports best practice to achieve target mix of planned (70%) vs. other (30%) work
+ STO Benefits
• Completely Inside SAP – real time data
• No additional hardware or middleware
• Quick Implementation (as little as 3-4 weeks)
• SAP Certified
• Support is available 24/7
• Offices in US, UK, Brazil, South Africa, Australia
Technical & Implementation
Upcoming Events: PGU
Prometheus Group University (PGU) classes are designed to further your skills using Prometheus software and standard SAP.
July 26 – 29 | PG 101: Mastering ERP Advanced(Raleigh, North Carolina)
Aug. 30 – Sept. 2 | PM 102: World-Class Scheduling with SAP and Prometheus (Calgary, Alberta)
Sept. 27 – 30 | PM 201: Taking Plant Maintenance to the Next Level (Raleigh, North Carolina)
“I believe every one should have a class like this before working in SAP.”
- PGU attendee
Upcoming Events: User Conference
The Prometheus Group User Conference (PGUC) is an annual event that brings together users from across North America for 2.5 days of learning and networking centered around evolving EAM strategies.
www.userconference.prometheusgroup.com
“I enjoyed all the innovation that was demonstrated and especially best practices, tips and tricks. Enjoyed the mix and content of keynote speakers and individual workshops. Love
this conference and would recommend attendance to all.”
Questions?Thank you for joining us today.
Contact Us:Kevin Harp | [email protected]
Sean McWhirter | [email protected]
Visit us online: www.prometheusgroup.com
