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Turnaround/Shutdown Process implementation using PS/PM modules

Former Member
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We are a larger Size Fertilizer Industry, currently in the process of SAP Implementation. We carry out Annual Turnarounds each year for annual maintenance / overhauling of our equipment / machines.

The total numbers of maintenance jobs are around 1500. Each Job has an average 25 Operations. The Total duration of Turnaround is 15 Days max. Due to extensive number of jobs being handled in a very short time span, we require Planning with respect Job Execution and also related to material planning / Manpower / other internal & external services resource Planning. Moreover the Budget planning / control of the Turnaround is also part of our business.

The Planning of Turnaround starts 10 months before commencement of Turnaround. Starting from finalization of maintenance Jobs, material reservations, Budget Planning, Maintenance jobs scheduling in such a way to fit in all jobs within 15 days time span and develop a logical / technical viable links (relationship) between various operations within one job as well as between different jobs. Based on this relationship critical path is identified and activity Bar Chart is generated. The entire planned Project is then freeze as our target / base line and Planned S-Curve is generated. Before commencement of Turnaround, the material availability is ensured through monitoring of material procurement from Purchase requisition to Goods receipt.

Thereafter during Turnaround, the actual progress of maintenance jobs is monitored against the target plan on 12 hourly basis. Based on this monitoring we identify the activities lagging behind the Plan so that effective actions may be taken to expedite job progress. The daily progress is updated in terms of earned progress percentage. Moreover for management overview, Planned Vs actual S-Curve is generated.

IN SAP Scenario we are planning to configure our above process through PM / PS integration. Maintenance Work orders will be created for all jobs with reference to equipment Tag number to maintain history. Moreover, material and other resources will be attached to relevant orders / operations. Relationship between orders and their operations will be maintained. We intend to attach these orders Operations to PS Moreover we require bottom up scheduling using PS Planning board as mentioned below :

Operations Order Activity Network Header WBS element Project

We find ourselves handicapped to incorporate progress in terms of percentages, although we have managed to get percentage by putting duration of work completed on order operations level. However, getting percentage progress through duration input will not serve the purpose. Please refer following example:

u2022 An operation is planned for 100 hours.

u2022 During execution, 50% job completed in 20hours.

u2022 Remaining duration should appear as 50hours not as 80hours.

u2022 On contrary in SAP (as far as we know), if I put 50 hours in operation to get 50% progress , this will reflect wrong information as 50% job has been completed in 20 hours.

Can anybody suggest a solution in either PM,PS or combination of both modules.

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Answers (2)

Answers (2)

virendra_pal
Active Contributor
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you will need to use PM/PS as follows

Create a Shut down project

Create network activities for scheduling your shut down project

Create PM orders - which could be corrective action, planned, unplanned or preventive

Assign the order headers to network activity

Now you can use the PS scheduling functionality (bottom up planning as you require) - you will also see the PM orders on the planning board

For confirmation of activites you should use the forecast hours and this will correct the POC

The POC can be rolled up using Progress Analysis for your S Curves

Former Member
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Hi ABRARS,

your query is detailed & very useful.

Could you please tell me how did you overcome by this problem?

I integrated PS & PM module for the same scenario as yours.

Can you tell me detailed steps in carrying out shtdown activities which will very helpful to me..

Regards

Pradeep