second part of the presentation

Nilesh,

It is interresting question. You may need to set up many additional things apart from the Downtime indicator and Catalogue profile typically how to get proper reliability report.

SAP also promotes a partner product from Meridium and that is well integrated with PM & BW from SAP.

Attached presentation was recently delivered during Mastering SAP PM event at Austrelia. Hope it helps you. It has all the important steps and processes that required for good RCM project.

if you need some more help do not hesitate contacting me directly.

RGD

Thank Bob, I went thru 2nd presentation, the 1st part is corrupt.
Anyway, at present we are not looking for any software based RCM solution. We are planning to implement RCM with the use of existing CMMS (SAP PM) and most of pilot work will be paper based. With the presentation you had sent I am not able to extract what updation or checks I need to do in SAP PM, so that RCM data can be populated. During one of the meetings some one told me that Grouping of the technical object is a must to get proper MTTR/ MTBF report in SAP, but was not able to explain why? I need to know such requirement so that our pilot RCM project is success.

Thanks and regards

Nilesh:

With all of the CMMS/EAM programs, you must be cautious. In a great many cases the software is not fully populated or populated correctly. Regardless of vendor concepts of the CMMS/EAM providing all of the information that you need, it is not yet a reality.

Attached is a short essay from a series that I am running having to do with the future workforce and maintenance-management communication.

One of the keys to success is to ensure that you have input from the maintainers and operators from the associated equipment.

Sincerely,
Howard

Hello Nilesh,

Sorry for creating confusion here, I didnot sent the presentation to indicate that you should use that software, but just to indicate the process flow.

First overall Process that you want to set up should be clear, starting from RCM evaluation set up and till the end where you analyze the impact of its implementation and benifits it will bring in.

I agree with MotorDoc that you should involve Operator and Maintainers in setting up these process and all the criticle path help system can provide. EAM solution could be from SAP or ABC it should not matter.

Though I do not agree on many points in the "...corporate communication". Most of the failures of COTS based CMMS/EAM are because so many people misunderstand them. I think They are just tools, most of them are written by techies who has neither maintained any equipment nor managed any financial department of any company. They develop software based on what their customer ask for.

If processes in some compnies are ....... up CMMS can not do any thing. I am not a PhD but was just a simple maintainer in past so I may be wrong here.

Attachements are too big to be uploaded here, so write me a mail at bvental@yahoo.com if you need them.

RGD
Bob

What data are required for your rcm? If you could specify the data required for a proper rcm, this forum may be able to inform you better. Also please confirm that your rcm complies with J Moubray's RCMII or SAE rcm standard.

THANKS TO ALL
We do have plans to involve maintenance technicians and operators for the RCM deployment. We are following RCM2 as suggest by John M. We do have gone thru SAE JA1011 and SAE JA1012 standards; I found them to be very similar with JM's RCM2 and really could not differentiate except for the decision diagrams. SAE does not acknowledge any decision diagram and leaves it to the implementer.

We are at the stage where we are assessing our self for carrying out the RCM implementation and we need to clearly understand that if there is any mandatory setting or configuration which needs to be done in SAP (specifically) to get the proper input data for RCM. RCM input data would be MMTR, MTBF, cost of repair, asset technical history, etc. At this point I agree with the document sent by MotorDoc that there exist a large gap between CMMS and RCM business requirements.

Ok good that you have confirmed that we talk about the standard rcm. Now I'm not an rcm expert but I have used SAP PM for sometime. So I would like to know what raw data are required for rcm input data ie to calculate MMTR, MTBF ect. I understand you have to do some "data censorship" etc. Cost of repair can be captured in work orders. What do you mean by "asset technical history"? If the rcm business can specify what raw data do you require for rcm, may be the cmms community could response better to your rcm needs and close the large gap.

In order for your CMMS to be useful, you need to have a good maintenance work process in place, AND FOLLOW IT rigorously. If you don't follow your own process for collecting and storing data, it will be worse than not having any at all.

"Asset technical history" could mean equipment characteristics in the equipment record, or it could mean repair/maint history that should be captured in the notifications. MTTR for example, can be captured by using the Malfunction Start and Malfunction End date/time fields in the Malfunction Report or Activity Report (Notification) on the Malfunction Data tab. If you want to calculate MTBR (or MTBF, whichever you use), you can utilize the Breakdown box on the Malfuction Report or Activity Report. You can utilize the fields found on the Items tab of the Malfunction Report or Activity Report to keep track of what parts (maintinable items) have been failing, causes, and what was done about it. Unfortunately, all this info is not as easy to get back OUT for analysis as it is to put IN. There are some standard reports in SAP PM, but I believe some of them will not work correctly unless your database is configured a specific way. And since I believe we have that problem, I don't know how to make them work. If you have SAP BW (Business Warehouse) available, and have people who know how to use it effectively, you can build reports to pull the data you need, and even join it up with data from other sources that SAP won't "talk to".

One caution, reiterating advice from MotorDoc, and probably others...

Databases are nice to have...but it's the PEOPLE who really know what is going on. Not only the engineers who designed it, but the operators and mechanics and technicians that have to make it work every day. These people are your most important source of information/data in an RCM analysis.

Best wishes for a successful RCM program. (Just curious, you might have said before and I didn't catch it. Are you using RCM for new equipment/processes, or are you applying it to an existing system/plant?

Kim Williams

thanks KIM,
It is wonderful to get such info and Now I know where to start with. For your curiosity question - We are implementing RCM for an existing unit with three year old SAP PM database.

Thanks a Lot

Hello Nilesh,

Please allow me to introduce myself. My name is Kevin Sutherland and I am a Solutions Engineer at Meridium based in Roanoke Virginia. It appears that you have received some very good feedback from your initial request, including some slides of our RCMO product (thanks BobV).

I agree with the other posters that it is very important to have a good CMMS foundation in place, do an assessment to determine the assets with the greatest business risk, choose an appropriate RCM/FMEA methodology based on the asset risk, and include a diverse group of Subject Matter Experts in each analysis. At Meridium, we certainly don't think that these steps should be short circuited or be taken lightly.

The RCMO product, that you now have some information about, was created for 3 simple reasons. 1. No matter what RCM/FMEA methodology you choose, the outcomes of the process are useless unless they get implemented correctly into your CMMS (SAP). This has been very difficult in the past with stand-alone, disconnected systems.
2. When organizations spend time and money on RCM initiatives they want to insure that they are getting return on their investment. Many times organizations have no clear idea what their RCM initiatives have accomplished.
3. Plants are very dynamic environments, so we believe that maintenance strategies should be dynamic as well. Most RCM analyses are done as one-time exercises.
These are the specific challenges that RCMO was built to address.

If I can be of any assistance to you in your RCM endeavors, please don't hesitate to contact me at ksutherland@meridium.com.

Best Regards,

Kevin Sutherland
Solutions Engineer
Meridium, Inc.
+1-540-344-9205

Hi Nilesh, How was your pilot RCM implementation. I would like to hear your experience.

Mumbai, India

Dear Nilesh,

Please share your experience with us. We are also trying to implement the RCM with our old SAP database.

Please send some initiatives you taken to get things done at floor level.

Regards,

Jaigopal Soni

quote:

Originally posted by Nilesh Shrivastava:
thanks KIM,
It is wonderful to get such info and Now I know where to start with. For your curiosity question - We are implementing RCM for an existing unit with three year old SAP PM database.

Thanks a Lot

The most important thing is to upload your RCM analysis results into SAP PM.

This can mean replacing existing PMs with the new RCM analysis results or editing existing PMs to include the new RCM analysis results.

Also updating the asset criticality if this is revised during the RCM process.

So Nilesh, have you manged to upload your RCM analysis results into SAP PM?

If yes, any improvement on your maintenance and reliability KPIs?

Any reduction in the number of failures?

Those fields in SAP PM that need to be filled in by users are normally should be made mandatory fields whose values should be entered by users in order to facilitate or enable the final whatever analyses required or enquiries made at anytime.

In order to enable dynamic or continuous improvement of PMs in CMMS (either prepared based on OEM manual, experience or RCM), some standard reliability analyses would need to be carried out using some data from CMMS. So what are these standard reliability analyses that are commonly done for problem soivng and decision making purposes, if anyone can list them down?

Nilesh

By "grouping of technical object(s)", do you mean setting up the functional location hierarchy eg attach a pump to its driver say a motor?

Nilesh

What constitute the "cost of repair" in work orders in your site?