February 24 2021 Rising to the EAM Data
February 24, 2021 Rising to the EAM Data Challenge Strategic Master Data Across the Enterprise © 2019 DXC Technology Company. All rights reserved.
Enterprise data lives in multiple systems of record Reliability Systems • Business is transacted in real-time across connected devices and systems Engineering system • Digital twins must remain in sync to maintain data integrity SCADA GIS Content Management © 2019 DXC Technology Company. All rights reserved. Plant Maintenance February 24, 2021 2 PT_4371 a-20
High quality data enables the intelligent enterprise Influences every process Informs every decision High Quality Data Connects goals to outcomes Leverages technology investments Fuels collaboration © 2019 DXC Technology Company. All rights reserved. February 24, 2021 3 PT_4371 a-20
The reality is… Data gets dirty • Complexities • Diverse landscapes • Legacy systems • Regulatory changes • Rapid growth • M & A’s • Knowledge transfer • Siloed departments © 2019 DXC Technology Company. All rights reserved. February 24, 2021 4
The data quality gap 56% 8% 3% of CEOs are concerned about the quality of their data. of organizations have reached “transformational” levels of maturity in data and analytics. of company data meets a minimum threshold for data quality. Source: KPMG, 2017 Global CEO Outlook. Gartner, Survey Analysis: Traditional Approaches Dominate Data and Analytics Initiatives, Feb 5, 2018, Harvard Business Review, Only 3% of Companies’ Data Meets Basic Quality Standards, Sept 11, 2017. © 2019 DXC Technology Company. All rights reserved. February 24, 2021 5 PT_4371 a-20
Actionable data to outcomes Case Study 1 Large Polymers Manufacturer MRO SPARE PARTS/Inventory © 2019 DXC Technology Company. All rights reserved. February 24, 2021 6
MRO by the numbers • Annual spend of roughly $1. 5 billion in MRO Spares replenishment • 91% of work orders scheduled, require multiple trips and manual intervention • Over $150 m of MRO Spares Inventory with an annual carry cost of 25% • Only 31% of critical assets have accurate and complete MRO spares information © 2019 DXC Technology Company. All rights reserved. February 24, 2021 7
Obsolete inventory analysis Obsolete Inventory Analysis Mills / Plants MRO Spares Balance Sheet Annual Carrying Cost (25%) MRO Spares Annual Spend Camden MRO Spares Balance Sheet Annual Carrying Cost (25%) MRO Spares Annual Spend Site #1 Materials on BOM Potential Obsolete Materials % of Total Lack of Inventory and Required Critical Spares Potential Impact Value of Potential Obsolete Materials MRO Spares Balance Sheet Annual Carrying Cost (25%) All Sites Annual Carrying Costs 12 $150, 000. 00 $37, 500, 000. 00 $350, 000. 00 $12, 500, 000. 00 $3, 125, 000. 00 $29, 166, 666. 67 31, 962 19, 120 12, 842 40. 18% 75. 00% 10. 04% $1, 255, 592. 58 $313, 898. 14 $16, 322, 703. 52 $4, 080, 675. 88 © 2019 DXC Technology Company. All rights reserved. February 24, 2021 8 PT_4371 a-20
Wrench time and asset availability analysis Wrench time / Asset Availability Analysis Camden Total Equipment Total equipment with BOMs Current First Time call Resolution (%) New BOM's added to Equipment (automated) New BOM's added to Equipment (manual) New Total equipment with BOM's Future First Time Call Resolution % Utopia Impact 50, 399 15, 119 30% 4, 735 7, 636 27, 490 54. 55% 81. 83% © 2019 DXC Technology Company. All rights reserved. February 24, 2021 9 PT_4371 a-20
Actionable data to outcomes Case Study 2 Global petrochemical producer brownfield asset data quality Improvement © 2019 DXC Technology Company. All rights reserved. February 24, 2021 10
Key business challenges and value impacted by effective asset master data management Capital project/ turnaround delays $1 million/day per $billion in asset value 1. 5% of Capital Cost Information foundation creation 1 to 3% of capital project budget Reduce by 10– 20% Safety and environmental $1–$100 million Reduce incident risk and cost by 5% Plant availability North American refining capacity < 90% 1% increase in availability Shop floor productivity Wrench time averages 35% (world-class 60%) Improve by 50% Aging/mobile Workforce Before 2020, up to 50% of skilled shop floor workforce will retire Increase knowledge capture Absorb attrition MRO supply chain disconnected from shop floor Less than 50% of MRO materials are in equipment bills of materials Reduce obsolete items (3%) Reduce parts consumption (2%) Reduce returns (30%) Low adoption of MRO systems Low adoption rates for 60% of workforce (operators/craftsmen) Reduce training costs ** Potential benefit from improved asset master data management. © 2019 DXC Technology Company. All rights reserved. February 24, 2021 11 PT_4371 a-20
Brownfield improvement program • Only 40% of their equipment to be in SAP Plant Maintenance • Field walkdowns underway to collect brass tags • Outsourced Machine learning to classify/cleanse/enrich • Insourced/Outsourced manual enrichment for remaining data • Accelerate 4 -5 year program to 12– 18 months • Focus on Critical Equipment, then expand © 2019 DXC Technology Company. All rights reserved. February 24, 2021 12
From MRO spares to plant maintenance Maintaining your data quality initiatives throughout the value chain © 2019 DXC Technology Company. All rights reserved. February 24, 2021 13
The Business Case for Asset Master Data Quality Ensuring accurate, complete asset master data can have a direct impact on reducing environmental, health & safety risks, improving operational performance and maintaining regulatory compliance. Maintenance Inefficiency • • • Operational Inefficiency Reduced maintenance ‘wrench-time’ Inadequate preventive maintenance Poor visibility into asset lifecycle Excessive MRO Supply Chain Costs • • • Increased downtime from equipment failure Increased mean-time-to-repair Raw material shrinkage • Safety risks for maintenance staff and operators Inadequate risk management & quality assurance Increased EH&S Risks Inability to accurately predict spares needs Unidentified obsolete inventories Excessive expedited procurement Lack of Auditability • Inability to Achieve Operational Excellence • • • Poor financial accountability Regulatory compliance risk Product liability risks from quality © 2019 DXC Technology Company. All rights reserved. • Inability to achieve top quartile performance through advanced maintenance techniques such as reliability-centered-maintenance, risk-based inspection, performance analytics February 24, 2021 14 PT_4371 a-20
Understanding the Business Challenge Maintaining an accurate, complete Digital Twin in the key systems of record can have a direct impact on reducing environmental, health & safety risks, improving operational performance and ensuring regulatory compliance. The Challenges • The assets are continuously changing (maintenance, shutdowns/ turnarounds, capital projects) Reliability SCADA Engineering GIS • The Digital Twin includes unstructured data (Operating Manuals, Repair Manuals, Warranties) Content Management • The Digital Twin is distributed among multiple systems of record © 2019 DXC Technology Company. All rights reserved. Plant Maintenance February 24, 2021 15 PT_4371 a-20
Understanding the Business Challenge Maintaining an accurate, complete Digital Twin in the key systems of record can have a direct impact on reducing environmental, health & safety risks, improving operational performance and ensuring regulatory compliance. Reliability Engineering The Challenges • The assets are continuously changing (maintenance, shutdowns/ turnarounds, capital projects) GIS SCADA • The Digital Twin includes unstructured data (Operating Manuals, Repair Manuals, Warranties) • The Digital Twin is distributed among multiple systems of record Ensuring Synchronization of The Network of Digital Twins is essential to Safety, Efficiency and Operational Integrity. Content Management “ “ © 2019 DXC Technology Company. All rights reserved. Plant Maintenance February 24, 2021 16 PT_4371 a-20
Example: The Digital Twin Full end-to-end cycle of creating, enriching, validating and approving a new equipment master using SAP AIN and SAP Asset Information Workbench Physical Asset Digital Twin Electrical Power Cool Air Water Outlet Driver Condenser Compressor Dryer Refrigerant Accumulator Boundary © 2019 DXC Technology Company. All rights reserved. Controlling and Monitoring Water Inlet Pump Miscellaneous Power Remote Instrumentation February 24, 2021 17 PT_4371 a-20
Example: The Source for the Digital Twin Electrical Power Cool Air Water Outlet Driver Condenser Compressor Dryer Refrigerant Accumulator Boundary Controlling and Monitoring Water Inlet Pump Miscellaneous Power Remote Instrumentation © 2019 DXC Technology Company. All rights reserved. February 24, 2021 18 PT_4371 a-20
Example: From Brass Tag to Digital Twin in SAP • Customer supplied Brass-Tags (photos) from plant walk-down to Utopia for data enrichment • Utopia placed the information in the SAP Asset Intelligence Network for easy access “Brass tag” enriched data Noun CHILLER Modifier AIR COOLED CHILLER AIR COOLED CHILLER AIR COOLED CHILLER AIR COOLED Attribute name TYPE NOM COOLING CAPACITY NOM HEATING CAPACITY NOM COOLING TOTAL INPUT POWER NOM HEATING TOTAL INPUT POWER NOM COOLING RUNNING CURRENT NOM HEATING RUNNING CURRENT REFRIGERANT TYPE ELECTRICAL RATINGS Attribute value INVERTER 50000 BTU/H 55000 BTU/H 7600 W Short description Long description CHILLER: AIR COOLED; TYPE: INVERTER, NOM COOLING CAPACITY: 50000 BTU/H, NOM HEATING CAPACITY: 55000 BTU/H, NOM 6100 W COOLING TOTAL INPUT POWER: 7600 W, NOM HEATING 15. 2 A TOTAL INPUT POWER: 6100 W, NOM COOLING RUNNING CHILLER: AIR CURRENT: 15. 2 A, NOM HEATING 13. 1 A COOLED; INVRTR, 500 RUNNING CURRRENT: 13. 1 A, REGRIGERANT 00 BTU/H R 410 A TYPE: R 410 A, ELECTRICAL 380 TO 415 VAC, 50 RATINGS: 380 TO 415 VAC, 50 HZ, 3 PH, COMPRESSOR TYPE SCROLL TYPE: SCROLL, COMPRESSOR CONTROL 0 TO 55000 BTU/H CONTROL CAPACITY: 0 TO 55000 CAPACITY BTU/H, EVAPORATOR COOLING WATER FLOW: 0. 7 EVAPORATOR COOLING WATER 0. 7 L/S, EVAPORATOR HEATING FLOW WATER FLOW: 0. 8 L/S EVAPORATOR HEATING WATER 0. 8 L/S FLOW © 2019 DXC Technology Company. All rights reserved. http: //www. acson-international. com/files/tm/mcquay/Mc. Quay%20 TM 2007/M 5 ACV-2007. pdf February 24, 2021 19 PT_4371 a-20
Integrated Object Model – SAP Master Data Governance Profit Center/ Hierarchies General Data Comp. Code Data Purchasing Data Sales Area Data Company Consolidation: Item, Group & Hierarchies, Unit, Break Down Category Customer Attributes Document Link Plant Data Storage & Warehouse Data Contract Account Attributes* General Data Functional Location Valuation, Costing, Material Ledger Maintenance Plans Maintenance Plan Items Measuring Points Task Lists Service Master Header: Identifying and Quantity, Validity Data, Material Data, Texts Item: Detail, Quantity, Status, MRP and Purchasing Data, Text and Document Assignment © 2019 DXC Technology Company. All rights reserved. Basic & Classification Data Classification Production Version Partner-specific Data Equipment Master EAN, UPC Sales Data Tax Indicators Work Centers Descriptions Units of Measure Tax Bill of Material Characteristics Assignment & Variants Purchas. Business Partner Relationships Quality Data Products Purchase Info Record Logistics, Listing, Sales Addresses with Usage and Versions Supplier Attributes Cost Center/ Hierarchies Industry Sectors Asset Structures Tax Numbers Units of Measure Work Management Objects Identification General Data & Descriptions MRO Bill of Material Bank Details Basic & Classification Data Cost Element/ Hierarchies Roles Logistics Data Financial Reporting Structures: Balance Sheet, P&L Statement Business Partner Attributes Central Data Assets Material Linear Asset Capabilities Accounting , Controlling and Consolidation GL Account/ Chart of Accounts Supplier & Customer Value Finance Stores Purch. Org / Vendor / Site Distribution Center Listing Sales Org. Data Point of Sales February 24, 2021 20 PT_4371 a-20
SAP Asset Information Workbench Integration points 1 EPCs / Contractors On Premise Asset Intelligence Network** Asset Information Workbench As-built CAD, Equipment Lists Best Practices Libraries 2 Manufacturers / OEMs Catalogs, Specifications 3 Transmittal Management Content Request w/ Smart. Match Approved Multi-Object Change Requests 5 Data Collection Forms 6 Governance Rules & Workflows Asset Information Staging Area (MOCR)* Systems of Record Content Management 7 Engineering 3 rd Party Libraries Switches, O-Rings, Seals, Bearings Sensors, Cylinders, Tools, Motors 4 3 rd Party Data Suppliers Plant Maintenance Release To Operations Digital Service Request Business Rules 8 GIS SCADA SAP Master Data Governance, EAMx *Multi-Object Change Request. **Integration provided by Utopia. © 2019 DXC Technology Company. All rights reserved. February 24, 2021 21 PT_4371 a-20
Conclusion • Data is critical to success of organizations • Linking data improvement to tangible outcomes drives investment • Analysis of data and careful laying out of real-world risks and opportunities related to that improvement drives organizational change • UTOPIA and DXC OXYGEN CAN HELP © 2019 DXC Technology Company. All rights reserved. February 24, 2021 22
© 2019 DXC Technology Company. All rights reserved.
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