8.1 Materials Management

2012 PEM Magazine Maintenance Awardo Plant Engineering & Maintenance magazineo Best use of Technology/Maintenance Innovation categoryo Production Loss Tracing systemo Published March/April 2013 edition of PEM magazine

In a long career implementing and improving SAP SCM business processes in Oil & Gas, Pipelines, Utilities and Transportation companies, the number one consistently observed problem is poorly identified MRO material masters. Material master identity consists of the item descriptions, the manufacturer and manufacturer part number fields and classification data that support material identification. This presentation is meant to raise the profile of the topic without going into detailed solutions. It is aimed at a general level to all practitioners that make use of maintenance or SCM business processes that use materials. The presentation is software agnostic. These challenges are found in shops running SAP, Oracle, JDE, Maximo…Topics: • Introduction (discussion applies to asset intensive industry and the MRO materials records used in their supporting business processes)  • Generalized view of the current state and how we arrived here. • Structured identification taxonomy – standards and why coherence in the structure is important. • Material master lifecycles are often not considered- beginning, middle, end. • Conclusions: This is not an insolvable problem or one that necessarily demands another $$$ system implementation. It exists only because it has been invisible  Originally Presented at AB Chapter Online Symposium (Part 1 of 7)  05/28/2020  as "The Story of My Journey With MRO Material Master Identities."  Presented MainTrain 2020  09/15/2020

Enbridge Liquids Pipelines is at the midpoint of a multi-year journey to advance the M&R program for its electrical and mechanical assets. This presentation will share successes and challenges while aiming to apply M&R best practices to a midstream pipeline operator. Our initiative will improve M&R processes and culture, with a focus on improving multiple work streams. These include the planning, scheduling, and execution of preventative and predictive maintenance, information management, spare parts, and CMMS use.

This case study will show how we used an analysis of standard work management metrics and a systematic approach to identify opportunities to improve our plant. We'll provide specific examples of how we developed and implemented the approach and the results we achieved. We'll also describe the fundamental understanding and steps that could be taken to implement a similar approach at any plant, or for any particular metric. Topics will include cultural recognition of KPIs as an improvement tool, not a personnel measurement stick; understanding all the various causes and influences on any particular metric; analysis and categorization of deviations; identifying losses as acute one-offs vs. chronic systemic issues; behavioural vs. procedural issues; understanding change/improvement requirements, what can be directly controlled and what can be only influenced; determining corrective actions; and tracking the resulting improvements. Specific examples will be derived from our site's application of this methodology to schedule compliance, PM/PdM compliance, and emergency work metrics.  

Setting up or organizing a storeroom is a major undertaking, but it has the ability to dramatically impact the ability of the storeroom to deliver its function.   Sadly, many storerooms are not organized properly and are forced into specific accommodations.   But armed with some basic information, you will be able to setup a proper storeroom.

A Risk-Based Approach to Spares Management 

While a host of factors influence profitability, maximizing your plant’s production output potential is arguably one of the facility’s greatest opportunities. An Asset Management, Reliability and Maintenance Strategic Plan can guide continuous improvement that’s aligned with bottom-line performance expectations for managing assets and people. This presentation will provide a framework approach for establishing your strategic asset management & reliability plan and the associated business case. Delegates will gain a fundamental understanding of how to establish a baseline: "know where you are," define where you’re going, who needs to be involved, how to measure the program’s progress and results, and what elements are essential for success.

"Uptime - Strategies for Excellence in Maintenance Management" has been a best-seller since 1995. It's 3rd edition includes a number of significant changes from the earlier editions reflecting changes in successful practices, the emerging field of Asset Management and the new imperative that any changes become sustainable. This workshop will provide an overview of the new Uptime "Model of Excellence," introduce the book's new material, explain how it all works and fits within the broader asset management framework.

There is “hidden” money available in most companies’ invested MRO (spare parts) inventory. It is not difficult to identify that inventory, but one must understand how it got there and how to avoid it “rebuilding” itself in order to take full advantage of the dollars that can be saved and spending that can be further avoided. This presentation will cover those key elements and also discuss, in detail, the nine phases of the MRO Lifecycle that one has to fully understand in order to take advantage of this savings potential. Use of a state-of-the-art CMMS/EAM system is paramount in collecting the right data to make the right decisions.