bt10 hagler optimizing equipment life cycle enterprise asset management
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As much as 50% of capital investment in newequipment is made to compensate for theunderperformance of existing equipment.
Reputation Customer satisfaction
Repeat business
Competitive advantage
Why Focus on Asset Reliability
Optimizing Equipment Lifecycle: Enterprise Asset Management
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What is Equipment Life Cycle?
Optimizing Equipment Lifecycle: Enterprise Asset Management
Commission
Operate
Maintain
Retire / Replace
Design
Construct
Equipment & Asset
Life-Cycle
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Cost savings
- Reduction in maintenance expense 10% to 30%
Areas of savings
- Increase in production yield 3% to 5%- Reduced maintenance downtime 20% to 40%
- Reduced scrap / rework 5% to 10%
- Reduction in annual purchases 5% to 15%
- Improved labor utilization 10% to 30%
- Increased equipment service life 2 years
Why Optimize Equipment Life Cycle?
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Project controls
Asset management
- Plant maintenance
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MRO / spares inventory- MRO purchasing
How QAD EAM Assists
Optimizing Equipment Lifecycle: Enterprise Asset Management
EAM Project Controls
EAM Asset Management
Commission
Operate
Maintain
Retire /
Replace
Design
Construct
Equipment& Asset
Life-Cycle
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AP recorded, spreadsheets
Last updated?
Purchase costs only?
Internal labor? Internal materials?
Subcontractor services?
True acquisition cost?
Project Engineering Challenges
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Spending control
- Electronic workflow approval
- Spending alert notification
- Provide segregation of duties
Project work breakdownstructure
Customer projects
- Customer reimbursements
-Scheduled supplier payments
- Margin
EAM Project Controls: Key Capabilities
Optimizing Equipment Lifecycle: Enterprise Asset Management
EAM Project Controls
EAM Asset Management
Commission
Operate
Maintain
Retire /
Replace
Design
Construct
Equipment& Asset
Life-Cycle
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Manufacturing
- Inventory master
- Work order costs
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BOM Service and support
management
EAM Project Controls: Roadmap
Optimizing Equipment Lifecycle: Enterprise Asset Management
EAM Project Controls
EAM Asset Management
Commission
Operate
Maintain
Retire /
Replace
Design
Construct
Equipment& Asset
Life-Cycle
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Overall equipment effectiveness (OEE)
- Global average is 55%
Average unplanned / reactive work is 55%
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World class is
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Supports preventativemaintenance (PM) / PDM
PMs triggered based on actual
production
Analyze repair costs for labor,material and contractor
expenses
Measure mean time between
failure (MTBF)
Breakdown alerts via email orpage
EAM Plant Maintenance: Key Capabilities
Optimizing Equipment Lifecycle: Enterprise Asset Management
EAM Project Controls
EAM Asset Management
Commission
Operate
Maintain
Retire /
Replace
Design
Construct
Equipment& Asset
Life-Cycle
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Annual MRO purchases can equal 1% to 5% ofrevenue
In most cases, MRO is expensed at receipt
Unnecessary or incorrect purchases can range
from 10% to 25%
As much as 30% of MRO inventory is obsolete
Typical MRO Environment
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Manage company catalogfor MRO items
Automatic stock replenish
Supplier price schedules
Consignment inventory
Transfer parts across plants
Request for quote (RFQ)
Requisition approvalworkflow
EAM MRO: Key Capabilities
Optimizing Equipment Lifecycle: Enterprise Asset Management
EAM Project Controls
EAM Asset Management
Commission
Operate
Maintain
Retire /
Replace
Design
Construct
Equipment& Asset
Life-Cycle
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Share RFQ with suppliers via SC Portal
Contract purchasing
EAM MRO: Roadmap
Optimizing Equipment Lifecycle: Enterprise Asset Management
EAM Project Controls
EAM Asset Management
Commission
Operate
Maintain
Retire /
Replace
Design
Construct
Equipment& Asset
Life-Cycle
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Make better decisions
Support intentional decisionmaking
- from preparation
- to decision making
- to implementation
Manage by Fact
Improve shareholder value
EAM: Business Intelligence
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An out-of-the-box, performance management toolthat instantly transforms transactional data fromEAM into visually-depicted trends.
EAM Roadmap: Business Intelligence
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Start with a high-level KPI
EAM Roadmap: Business Intelligence
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Drill-down to further detail
EAM Roadmap: Business Intelligence
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Drill-down to further detail
EAM Roadmap: Business Intelligence
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Projects
Cash flow forecast
Expenditure analysis
Budget summary
Indirect purchasing Spending analysis
Spending by equipment
Purchases by vendor
Purchases by commodity
Rush orders
Late receipts
MRO inventory
Inventory turns
Slow moving inventory
Inventory value trends
Stock out analysis
Financials
Operational expense cashflow
Actual vs. Budget
Top cost center by % ofbudget
EAM Roadmap: Business Intelligence
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Maintenance
Top equipment by cost andby MTBF
Top equipment failures
Top reason by downtime Planned vs. Unplanned work
orders
Planned vs. unplannedlabor hours
PM vs. CM work orders
Work order count by priority
Equipment availability
Maintenance (by period)
Total maintenance cost
Service request count
Work order backlog
Count
Labor hours
Average days open
PM compliance
EAM Roadmap: Business Intelligence
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March 2011: general available (GA)
Supported versions
- 2007 SE through 2010 SE
- 2007 EE through 2011 EE
QAD EAM Status
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Project controls- Bring projects in on-time and within budget
- Control excessive spending
Plant maintenance
- Increase equipment efficiency
- Lower cost of repairs
MRO inventory and purchasing
- Right-sizing inventory lowering obsolete items
- Minimize stock-out thereby limited equipment
downtime
- Eliminate unnecessary purchases
Review
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Metrics Affected
Optimizing Equipment Lifecycle: Enterprise Asset Management
Process Benefit Value
Manage PM Production yield
Scrap / rework
Equipment service life
+10 to 20%
-20 to 50%
+10 to 20%
Manage labor resources Labor utilization +10 to 25%
Manage uptime Maintenance downtime
Production yield
-20 to 50%
+10 to 20%
Optimize inventory Inventory value - availability,common across plants
Stock-outs
-20 to 30%
-30 to 50%
Manage spend Annual purchases -10 to 20%
Officially source items Approved suppliers, bestprice
- 5 to 10%
Control project costs Manage costs withinbudget
Save services
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Get involved in customer advisory groups
Stop by the EXPO for a demo
Ask your account manager for an EAM
QScan
Next Steps
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