Reliability Dynamics ISPM Solution for SAP

ISPMTM

Equipment Taxonomy and Failure Reporting

Document No. SOTF0100 Solution Overview Issue Date: 16-Sep-2011

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Reliability Dynamics LLC © Reliability Dynamics LLC 2011

Table of Contents

Table of Figures ...................................................................................................................................................................... 1

1 Revision History ............................................................................................................................................................. 2

2 Approvals ........................................................................................................................................................................ 2

3 Reviews ........................................................................................................................................................................... 2

4 Background Information ................................................................................................................................................. 2

5 ISPM Solution Overview ................................................................................................................................................ 3

6 Equipment Taxonomy and Failure Reporting: Solution Details ..................................................................................... 4

6.1 Equipment taxonomy .............................................................................................................................................. 4

6.2 Equipment failure (malfunction) reporting ............................................................................................................. 4

7 Products and Services ..................................................................................................................................................... 6

End Notes ................................................................................................................................................................................ 6

Table of Figures

Figure 5-1: 1.1 ISPMTM ISO 14224 Centric Equipment Reliability Processes .................................................................... 3

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1 Revision History

Version Date of Change Changed By Description of Change

0.1 16-Sep-2011 Tony Ciliberti Prepare original document

0.2 08-Aug-2013 Tony Ciliberti Content review and update

2 Approvals

Stakeholders Name Date

Business Sponsors

Project Management

Reliability Dynamics Tony Ciliberti

3 Reviews

Stakeholders Name Date

Business Sponsors

Project Management

4 Background Information The Industry Standard Solution for Plant Maintenance (ISPM) is a preconfigured solution within SAP software for

equipment taxonomy and failure reporting. ISPM helps companies maximize production throughput and minimize

hazards with high quality equipment reliability data. With the ISPM product, companies can quickly identify and address

bad actor and pattern equipment failures that affect production or cause hazards. Whereas traditional solutions

account for only actual equipment repair costs (approximately ten percent of revenue loss), ISPM gives companies the

tools to account for all consequences related to each equipment failure: production loss, health, safety, and

environmental incidents, and repair costs. With ISPM, companies can also account for potential “near-miss”

consequences.

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ISPM greatly improves quality and accessibility of equipment reliability data with standard data collection processes and

by structuring data in relational format. High-quality structured data enable fast and comprehensive analyses. Whereas

non-relational failure data (typical of traditional solutions) must be analyzed one record at a time, with ISPM, thousands

of failure events can be queried simultaneously. Companies use that information to identity high-consequence

equipment failures and failure patterns, determine underlying failure details and systemic problems, develop

maintenance strategies, and take corrective actions. This truly gives companies the ability to make data-driven

decisions.

Equipment taxonomy and failure reporting are a subset of the ISPM solution.

5 ISPM Solution Overview ISPM Figure 5-1 gives a comprehensive overview of ISPM processes and designates aspects relevant to taxonomy and

failure reporting.

Figure 5-1: 1.1 ISPMTM ISO 14224 Centric Equipment Reliability Processes

Equipment malfunction reports· Standard data collection

processes· Minimum data capture (ISO

14224 Tables 6 and 8)

Classification of individual failure events· Consequence(s) of failure –

qualitative matrix (ISO 14224 Table C.1)

· Lost production amount (BBL)

· Affected equipment/unit(s)· Other as required by

customer (standard class functionality)

Multi-level failure reporting process (MLFRTM)· Work execution at the

component level· Failure reporting at the

equipment level (ISO 14224 Table 6)

Simplified failure metrics (standard SAP reports)

Standard failure coding(ISO 14224 Annexes A and B)· Catalog profiles used to

define equipment boundaries and for specificity of codes to equipment classes

Equipment taxonomy· Structurally

synchronized with equipment subdivision (ISO 14224 Annex A)

· Differentiates between functional and physical aspects of equipment (ISO 15926-2, Figs E.9 and E.10)

· Logical and systematic process for representing P&ID tag numbers

· Framework for efficient risk assessment

Operating context(ISO 14224 Table 5 and Annex A)· Used to identify how

equipment is used (process conditions)

· Integral parameter in failure metrics

Risk assessment· Similar to and integrated

with malfunction reporting (hypothetical vs. actual failure): same use of codes, operating context, classification, and reporting

Preventive Maintenance· Risk data used for strategy

development· Administration at area or

equipment level· Pass/Fail inspection verdict

recorded at equipment or component level

· Inspection verdicts used to optimize interval/scope

Malfunction reports generated for failures found via inspection

Color KeyTaxonomy and Failure Reporting

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6 Equipment Taxonomy and Failure Reporting: Solution Details The ISPM taxonomy structuring methodology (patent pending) is a tried and tested practical engineering solution

consistent with recommended and generally-accepted good engineering practice (RAGAGEP).

6.1 Equipment taxonomy 1. Structuring of equipment consistent with international standard practices ISO 14224i and ISO 15926-2ii

2. Intuitive navigation for users

3. Logical and comprehensive process for representing engineering tags in enterprise systems

3.1. Practical advice for determining which engineering tags should be represented in the system

3.2. Exact representation of engineering tags in the system

3.3. Both functional and physical aspects of each equipment tracked in the system as separate objects

3.3.1. Equipment (serial number) tracking

3.4. Functional object used as primary basis for risk assessment, preventive maintenance and inspections, and

as failure reporting

3.5. One unique ID for each object throughout all systems and records

3.5.1. Process functional specification/duty

3.5.2. Installed asset (serial number)

4. Functional location structure defines data relationships that can be processed by the system

4.1. ISO 14224 equipment boundary envelopes (equipment-to-component relationships)

4.2. Equipment-to-equipment interrelationships

4.3. Solution addresses issue of how to treat common facilities

5. Use/Location data (equipment operating context) used to classify equipment as to how it is used

5.1. Facilitates apples-to-apples comparisons of equipment performance across large datasets

6. Integrated and synchronized with the ISO 14224 failure coding process

6.1. Gives standardized results regardless of taxonomy complexity

6.2. Accommodates variations in reporting by personnel (equipment versus component)

6.2 Equipment failure (malfunction) reporting Standard process rigorously consistent with ISO 14224 methodology

1. Standard data collection processes

1.1. ISO 14224 failure coding synchronized with equipment taxonomy

1.2. Fully configurable data validations ensure consistent data collection from the field

1.2.1. Ensure malfunction reports are created at the proper levels (equipment and component levels)

1.2.2. Ensure required data fields are filled in the appropriate processing stage

1.2.2.1. Malfunction report processing stages

1.2.2.1.1. Problem report: notification of a new failure event

1.2.2.1.2. Repair report: repair action and failure consequences

1.2.2.1.3. Each processing stage is a separate business process with different positions/roles

responsible

1.2.3. Emphasis on data relevancy

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1.2.3.1. Failure coding is equipment class specific

1.2.3.2. Data specificity by processing stage

1.2.3.2.1. Display variants used to present only required data in each processing stage

1.3. Usability

1.3.1. Cockpit view: all information (long text descriptions, business process documents, reference materials,

etc.) needed by users is available directly from the malfunction report screen

1.3.1.1. NOT just SAP "throw-down" glossary text

1.3.2. Data relevancy measures, display variants, and class-specific coding greatly simply the failure reporting

process

1.3.3. User-friendly data validations make data checks pleasant for the user

1.3.4. Methodology-specific user help

1.3.4.1. Available directly from the failure reporting form as:

1.3.4.1.1. Failure coding descriptions (catalog group and code levels)

1.3.4.1.2. Field-level details (glossary text)

1.3.4.1.3. Business process document reference in MS Word format (via links in glossary text)

1.3.5. SAP Document Management Service (DMS) used to manage external documentation

1.4. Consequence assessment

1.4.1. Account for production losses and other consequences

1.4.1.1. Explicitly tied to the specific equipment failure events that cause those losses

1.4.1.2. User configurable for quantitative and/or qualitative data

1.4.1.2.1. E.g. consequence matrices

1.4.1.3. Quantitative (actual loss values)

1.4.2. Consistent with ISO 14224 process for consequence assessment (Table C.1)

1.4.2.1. Risk-ranking process also uses Table C.1 (with addition of a likelihood axis)

2. Cross-corporate failure metrics

2.1. Leverage standard-delivered SAP reports (almost no custom requirements)

2.2. Consistent reporting level defined as ISO 14224 equipment classes

2.2.1. Failure metrics for any given equipment item include all component failures (any failures reported

against component tags within the equipment boundary)

2.2.2. Made possible using Reliability Dynamics' patent pending Multi-level Failure Reporting Process

(MLFRTM) process.

2.2.3. Improves quality and availability of equipment failure data by making failure metrics and

consequences of failure explicitly available by simply generating a report (versus time-intensive data

mining).

2.3. Multi-variable cross-corporate reporting

2.3.1. Select results by any or all of the following:

2.3.1.1. Operating context

2.3.1.1.1. Equipment in like service can be quickly selected by ISO 14224 use/location data

2.3.1.2. Failure consequences

2.3.1.3. Failure details

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7 Products and Services 1. System assessment: what is right and wrong with your current solution

2. Methodology workshop: ISPM methodology rationale and fundamentals

3. Equipment taxonomy

3.1. Failure coding and characteristics

3.1.1. Standard schema for existing content in ISO 14224:2006 Annexes A, B, and C

3.1.1.1. Catalogs and catalog structures: general and equipment class specific codes

3.1.1.2. Classification structures (class identifiers and hierarchies)

3.1.1.2.1. Functional location

3.1.1.2.2. Equipment

3.1.1.2.3. Failure consequence classification

3.1.2. Extend ISO 14224 taxonomy with additional equipment groups, categories, classes, and class-types

3.1.2.1. New equipment classes developed using ISO 14224 methodology

3.1.2.1.1. Additional equipment classes available from Reliability Dynamics as standard content

3.1.2.1.2. Facility-specific equipment class development service available

3.1.2.1.2.1. Create taxonomy for equipment classes specific to your facility

3.1.2.1.2.1.1. Class development workshops in conjunction with your experts

3.2. System configuration

3.2.1. Master data settings and content for technical objects

3.3. Master data

3.3.1. Equipment taxonomy design and creation

3.3.1.1. Design and build intelligent functional location structures as described in Section 6.1.

3.3.2. Classifications structures: class hierarchies, characteristics complete with allowed values, new units of

measure as required, etc.

4. Malfunction reporting

4.1. System configuration

4.1.1. Malfunction Report: ISO 14224:2006 compliant

4.1.2. Maintenance Request

5. Development work

5.1. MLFR-related enhancements

5.2. s070 data structure fix

5.3. User help documentation

5.4. Conversion objects

End Notes i ISO 14224:2006, Petroleum, petrochemical and natural gas industries -- Collection and exchange of reliability and maintenance data for equipment ii SO 15926-2:2003, Industrial automation systems and integration -- Integration of life-cycle data for process plants including oil and gas production facilities -- Part 2: Data model (Figures E.9 and E.10).

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