Name: Denis Deschamps Position: Maintenance Business Process Specialist Department: Base Metals

Transcription

1 MPROC of 8 Training Code (If applicable): Document Owner: Name: Denis Deschamps Position: Maintenance Business Process Specialist Department: Base Metals Table of Contents.0 PURPOSE SCOPE EXCEPTIONS REFERENCES DEFINITIONS FUNCTIONAL LOCATION CRITICALITY EQUIPMENT CRITICALITY EQUIPMENT EXCEPTIONS REPORTING REPORTING FROM SAP REPORTING FROM BUSINESS OBJECTS APPENDICES APPENDIX A: ISION NOTES AND APPROVALS... 8

2 MPROC of 8.0 PURPOSE The purpose of this document is to outline the process to determine Functional Location Criticality and thus the criticality of related Equipment for use within SAP. Asset Management Framework (AMF) defines the process to define Productive Unit Criticality for the purpose of determining the Service Strategy of the Productive Unit. It takes into account the fact that not every Productive Unit, and thus the equipment within the Productive Unit, are the same in terms of cost, impact to Production, impact to the environment or safety as far as people or the assets are concerned. Other factors to consider when assigning Criticality to a Productive Unit are expected life, and quality of the pieces of equipment themselves within the Productive Unit. This process will help determine the right Service Strategy and review cycle for that asset by assigning a criticality ranking to it. The intent of this document is to have a standardized process for all sites to use within Base Metals to determine the Criticality of a Functional Location as well as the serviceable objects within that Functional Location. 2.0 SCOPE This document pertains to the following SAP objects: Level 5 Functional Locations Equipment 2.. EXCEPTIONS This document does not pertain to Sub Equipment or Components Level -4 Functional Locations

3 MPROC of REFERENCES The following references were used in the development of this document. They shall be used in their most recent revision. VPS Vale Production System AMF Asset Management Framework o Set Asset Performance Target o TA 5.03 Identify critical productive units TA 5.04 Specify critical serviceable items (equipment/workplace) 4.0 DEFINITIONS Functional Location level 5 A logical grouping of Equipment that work to Transfer, Transform or Store a product or service Equipment An element of a Productive Unit that can transform, transfer or store a product or service on its own, but can be removed and repaired as an independent unit, and that performs a distinct function Maintenance Item A description of the maintenance and inspections tasks to be performed at maintenance objects, describing the dates and scope of the tasks

4 MPROC of FUNCTIONAL LOCATION CRITICALITY In the Asset Management Framework, process, Task Assignment Identify Critical Productive Units states that criticality should be assigned at the Productive Unit level, or at the level where equipment is grouped to produce a Transfer, Transform or Store process. In SAP this is called a Functional Location. A Customer Enhancement Item Tab has been created within Maintenance Items in our SAP system to support the - Asset Integrity process within AMF. This tab will also be used to assign the Criticality to the Functional Location Using IH0 find all level 5 Functional Locations. These are the lowest level of the Functional Location Hierarchy that has the actual equipment attached to it Using Cheat Sheet Maintenance Item - Create Maintenance Item for Functional Location Criticality - IP04, create maintenance items for all Level 5 Functional Locations o These items will not be scheduled but are being used to hold the data related to calculating the Functional Location Criticality When creating the Maintenance item, the Consequence Ranking matrix from TA 5.03 should be used to determine o HSE ranking Safety Environment o Business Ranking Planned Plant Production Vale Canada Revenue Loss Direct Cost of Repair Regulatory Compliance Social Save these in the Maintenance Item (do not click on Calculate) To view the Functional Location HSE and Business rankings run P2D-M-050-SAP-Functional Location Criticality Ranking-v.0-BM Report Functional Location Criticality Ranking This Report will assign a numeric Value to each Function Location within your plant

5 MPROC of 8 The SAP Functional Location register contains all Master data related to that Functional Location. Included in the dataset is a Criticality field with 3 options (A, B, C). Populate this field for all Functional Locations using the Pareto principles where 80% of the Risk would come from 20% of the Functional locations, you would assign roughly 20% to Criticality A, B and the remainder C based on the Consequence Ranking calculated in the Business Objects Report. Assign the criticality Ranking based on: o A Roughly one third of the 20% of Functional Locations with the highest ranking o B Roughly two thirds of the 20% of the Functional Locations with the highest ranking. o C all other Functional Locations 6.0 EQUIPMENT CRITICALITY The SAP Equipment register contains all Master data related to that unique piece of equipment. Included in the dataset is a Criticality field with 3 options (A, B, C). Cascade the criticality from the Functional Location to all Equipment within the Functional Location: A to all equipment where the Functional Location has a Criticality of A B to all equipment where the Functional Location has a Criticality of B C to all equipment where the Functional Location has a Criticality of C 6.. EQUIPMENT EXCEPTIONS As with any process, there are variables. There are some pieces of equipment within a Functional Location that have been identified as Criticality A where the equipment is part of the process but is not critical to the process and vice versa. This exception should be handled as one of and they should have their own Maintenance Items created to justify their exception status.

6 MPROC of REPORTING 7.. REPORTING FROM SAP Transaction IP8 Display Maintenance Item is used to display Maintenance Item information REPORTING FROM BUSINESS OBJECTS In the Business Objects environment, use reports: P2D-M-xxx-SAP-Functional Location Criticality Ranking P2D-M-xxx-SAP-Exception Equipment Criticality Ranking

7 MPROC of APPENDICES APPENDIX A: Revision Notes and Approvals

8 MPROC of APPENDIX A: ISION NOTES AND APPROVALS Revision notes describe: what was changed, and if applicable, why it was changed, and the plan to implement the change, including whether changes are retroactive. Note: The revision notes are a summary of the changes and may not necessarily be a complete list. Rev Revision Notes New Base Metals standard procedure. Reviewed and approved by the Base Metals Community of Practice membership. Document Review & Approvals Name and Positions Dated Document Owner Denis Deschamps Base Metals Business Process Specialist July 3, 207 Canada/UK Base Metals Heiko Leers Base Metals Maintenance Focal Point Aug 6, 207