aveline. optimized maintenance planning gersis v3

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Optimized Maintenance Planning

Gersis Software LLC


Maintenance planning in Oil&Gas. Problem statement

Problem scale:• More than 300 000 equipment units• 1 million man-hours for preventive maintenance• 0.5 million man-hours for reactive maintenance• >100 work orders per day• Forecasting for 10-20 years forward

Problems:• Equipment downtime should be as low as possible• Manual planning is difficult and error-prone• Errors cost millions of dollars• There are a lot of factors to consider (season, equipment

availability, relationships, etc.)


Aveline. Maintenance planning platform

• Software platform for automated planning• Automated planning in two modes:

– Strategic: long term planning (strategic)– Tactical: short term planning (tactical)

• Can be customized for specific needs• Uses data from existing ERP (SAP or other)


Aveline and SAP

Data Management in SAP – Automatic scheduling in Aveline.


Strategic Mode. Problem statement

• There are about 50 000 maintenance units

• Optimized resource forecast is to be done for 10-20 years ahead.

• A lot of factors to be considered (labor effectiveness, seasonality, etc.)

• Manual planning leads to forecast with workload peaks and idle times which cost the money


Strategic Mode. Example of possible losses

• Assume full cost of one man-hour equal 50$• Example existing forecast (based on real data): 10

years, ~350 maintenance units• Forecast has about 73,000 man-hours of overwork

and about 73,000 man-hours of idle time.

• Possible losses are about 7,5 million $.


Strategic Mode. Automated planning in Aveline

• Aveline automatically generates leveled man-resource forecast

• Aveline takes into account existing business rules (seasonality, monthly labor effectiveness, duty/standby equipment, etc.)


Tactical Mode. Problem statement

• Amount of work is always more than available resources

• There are hundreds of thousands of equipment and thousands of tasks. It is very difficult and error-prone to schedule them manually

• Aveline optimizes resource utilization and automatically schedules as much work as possible with available resources

• Aveline takes into account existing business constraints (Duty/Standby constraints, relationships between Operations, etc.)


Summary. Expected benefit

We expect reduction of work backlog by 20% as the result of optimized resource usage and work grouping. This results in: • Estimated decrease of equipment downtime by 5-10%• Increase of man-power utilization.• Reduced probability of equipment failure

Reference information:• Estimated revenue for one line for the gas production is

about 10,000$ per minute (14$ million per day).


Before we start. Glossary

• Work Order – combination of equipments and operations, which should be done on these equipments.

• Work Center – group of workers with similar skills (mechanics, electricians and etc.).

• Scope – set of Work Orders, which will be scheduled together, and period, for which schedule will be created.

• Planner Group - group of employees responsible for planning and processing maintenance tasks.


Work Scheduling Workflow

Import data from SAP

Prepare data

Create Scope

Adjust Scope

Automatic Scheduling

Final Tuning Consolidation

Export Results to SAP



SAP already contains information, which Aveline needs to work with:• Maintenance Items• Work Centers• Functional Location• Production Resources and Tools (PRT)

Aveline automatically imports data from files produced by SAP


Create Scope. Select Maintenance Items and Scheduling Period

• Aveline allows to define Scope name and description.

• Aveline allows to select scheduling period, for which Scope will be created.


Create Scope. Select Planner Group and Scheduling Period


Create Scope. Select Maintenance Items for scheduling

• As the next step User decides which Maintenance Items are to be included to Scope.

• Possible sources of Maintenance Items are– Maintenance Store– Local files– SAP

• Aveline also allows to include or exclude some Maintenance Items manually.


Create Scope. Select Maintenance Items for scheduling


Adjust Scope. Fix Maintenance Items

• Some Maintenance Items should stay fixed (automatic scheduling should not affect schedule defined by User).For example, some jobs should be completed in specific month.

• Aveline allows to fix Maintenance Items and their Scheduling Start Date will not be changed during automatic scheduling,

• Scheduler still have possibility to change it manually.


Adjust Scope. Fix Maintenance Items


Adjust Scope. Create/Edit Maintenance Item Packages

• Maintenance Items can be related. Scheduler may want to complete them in predefined order (at the same time or with some shift).

For example, operations for the same equipment can be grouped in order to shorten maintenance cycle.

• Aveline allows to create Maintenance Item Packages and change shifts between their Maintenance Items.


Adjust Scope. Create/Edit Maintenance Item Packages


Adjust Scope. Change Shifts


Additional Features. Seasonal Constraints

• Possibility to complete Maintenance Items frequently depends on season.

For example, it’s very dangerous to conduct any work around piping in a desert during summer.

• Aveline allows to create Seasonal Constraints, which define when jobs can be done, and assign them to Maintenance Items.


Additional Features. Create Seasonal Constraints


Additional Features. Assign Seasonal Constraints


Additional Features. Monthly Labor Effectiveness

• Workers efficiency/effectiveness for each month is different.

For example, Monthly Labor Effectiveness for August equals 50% as it is too hot to work the whole day.

• Aveline allows to configure value of workers effectiveness for each month.


Additional Features. Monthly Labor Effectiveness


Automatic Scheduling. Factors

During automatic scheduling Aveline

takes into account number of constraints:• Duty/Standby Constraints (describe when Duty

equipment should be turned off and which Standby equipment will work instead of it)

• Seasonal Constraints for specific Maintenance Items

• Relationships (shifts) between Maintenance Items

• Monthly Labor Effectiveness


Automatic Scheduling. Before Scheduling


Automatic Scheduling. After Scheduling


Automatic Scheduling. Work Cycle

2. Start Automatic Scheduling

3. Review Scheduling Results

Is Scheduler satisfied?

1.Configure Scheduling Scope


Adjust Scope. Configure Scheduling Parameters

• Overload for different Work Centres effects schedule quantity differently.


Final tuning. Check Violations

Aveline informs User about constraint violations (when business rule is not fulfilled):

• Seasonal Constraint Violations (Maintenance Items, which cannot be performed to given month because of weather conditions).

• Duty/Standby Violations (Maintenance Items, which cannot be performed to given month because of equipment state).



Aveline allows User to resolve constraint :

• Disable Seasonal Constraint• Exclude Maintenance Items

from Package or Scope• Unfix Maintenance Items and

Aveline will try to resolve violation during automatic scheduling.


Final tuning. Review Forecast

Aveline allows to review resource forecast for given schedule


Final tuning. Review Reports

Aveline allows to create report for given schedule variant.


Final tuning. Manual Scheduling

Aveline allows to use manual scheduling for final tuning


Consolidation

• Aveline allows to create lots of Scopes.

• It is necessary to review consolidated schedule for all Scopes to resolve resources clashes.

• Aveline allows to review forecast, reports and violations for Consolidated schedule.


Consolidation


Export data to SAP

• Prepared schedule should be exported to SAP

• Aveline allows to prepare files, which contain information about generated schedule and can be exported to SAP


Export data to SAP


Thanks!

aveline. optimized maintenance planning gersis v3

Data & Analytics

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reactive maintenance

preventive maintenance

maintenance units forecast

availableresources aveline

whichmaintenance items

possible manual planning

work orders