An effective end-to-end maintenance process is a cornerstone of a safe, reliable and efficient plant operation. In early 2017 several disparate business-led initiatives were being kicked off to improve performance of the Oil Sands business, specifically its costly maintenance processes from initial notification to execution and close out of work.
The SAP Solution Centre (SSC) saw an opportunity to partner with Oil Sands to manage these initiatives under one umbrella. The Maintenance Continuous Improvement Program (MCIP) was created as a result and the journey would continue over the next 1.5 years.
All aspects of people, streamlining business process, system enhancements/automation, reporting, sustainment and benefits realization were in scope. Accordingly, the MCIP was really a Maintenance business transformation exercise to improve the efficiency, safety and profitability of the Oil Sands business.
The end-to-end maintenance lifecycle was dissected one process block at a time using an agile project management approach. The SAP/IT team would facilitate lengthy discussion on current challenges, improvement opportunities and industry best practice with the Core Project team. The To-Be state would be refined several times before going to the Oil Sands Leadership Team for final review and approval.
In the end, the Maintenance Continuous Improvement Program has established a framework of best practice across the maintenance lifecycle. Several benefits such as greater productivity, efficiency as well as reduced costs and safety risk have already been realized.
Key Business Benefits:
- Clear definition of roles, responsibilities and accountabilities, eliminating gray areas
- Creation and publishing of maintenance schedule 14 days (T-2) before actual execution date, hence giving each stakeholders enough time to get prepared for the execution and achieving more than 70% schedule compliance
- Merging of 4 different Notification types into one to simplify the work request process
- Automatically populate Notification priority and Maintenance Activity type (MAT) based on RAMP (Risk Assessment Matrix Prioritization) criteria
- Automatic creation of 3 documentation folders in Notification using standard SAP document management functionality
- Agenda - 3:00
- Challenges Before This Project - 4:50
- Unique Concepts and Solutions Implemented - 11:30
- SAP Workflow - 24:20
- Defining and Tracking KPIs - 35:30
- Wrap Up - 38:30
- Ramesh Vora, Senior Business Analyst - SAP PM, CNOOC International