Download - BRD- MAINTENANCE

NBCL PLANT MAINTENANCE MODULE

COMPILED BY: ICST /16.07.15

DOCUMENT No. NBCL/1/ PLANT MAINTENANCE

NYANZA BOTTLING CO .LTD

Business Requirements Document

(BRD)

Prepared by: ICST- NBCL

Prepared for: Management -NBCL

Date Submitted:

Document Number: 1/ PLANT MAINTENANCE /BRD

Version: 0.1

Last Updated: July 16, 2015

Creation Date: July 16, 2015

NBCL PLANT MAINTENANCE



VERSION

Version Number

Prepared

By

0.1 SANGAM BADAJENA

PLANT MAINTENANCE MODULE

PLANT MAINTENANCE

VERSION UPDATED

Submitted

Date

Approved

By

Approval

Date

Description ofChange

Description of Change




TABLE OF CONTENTS

INTRODUCTION ................................

Purpose of a Requirements Analysis

Audience ................................

Stakeholder Identification ................................

Purpose of BRD ................................

Business Goal ................................

Benefits of BRD ................................

BUSINESS OVERVIEW ................................

Flow Chart ................................

Suggested ERP flow......................................................................

OEE Report Calculation...........................................................................

APPENDIX A: REQUIREMENTS ANALYSIS APPROV


PLANT MAINTENANCE

TABLE OF CONTENTS

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Purpose of a Requirements Analysis ..................................................................................

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flow...................................................................................................

OEE Report Calculation.............................................................................................

ENTS ANALYSIS APPROVAL .................................................

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1 INTRODUCTION

1.1 PURPOSE OF A REQUIREMENT

A requirement analysis document

for a new or altered PLANT MAINTENANCE

is the process of gathering information about business and technical requirements supporting a request,

consolidating this information into a cohesive document.

1.2 AUDIENCE

The audience for this document includes:

1. NBCL Management

2. Maintenance Department.

3. ICST-NBCL

4. ESS- Service Provider [i.e., developers who may participate in the requirements

Implementation of ERP Module]

1.3 STAKEHOLDER IDENTIFICATION

Stakeholder Name

Number of Individuals


PLANT MAINTENANCE

REQUIREMENT ANALYSIS

encompasses activities conducted to determine the needs or conditions

PLANT MAINTENANCE process. It commonly takes place after a request is received. It


consolidating this information into a cohesive document.

includes:-

developers who may participate in the requirements

CATION

Number of Individuals

Critical Success Factors

encompasses activities conducted to determine the needs or conditions

. It commonly takes place after a request is received. It


developers who may participate in the requirements at later stage for




1.4 PURPOSE OF BUSINESS REQUIREMENT

The main purpose of the BRD is to Implement ERP

current process in System.

1.5 BUSINESS GOALS / OBJECTIVES TO BE ACH

• Planned / preventive, repair, emergency and other user

• Ensure all materials, supplies and parts are available and accessible to maintain and service

equipment.

• Access existing or create new maintenance work orders from

and reporting

• Complete maintenance history and audit trail

• Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg

Spare inventory are consum

• Generate work orders and schedule

level) for planned maintenance

1.6 BENEFITS OF BRD

Through this BRD, one can analyze all process

ICST & Maintenance Team to switch all system in ERP with required Reports.


PLANT MAINTENANCE

USINESS REQUIREMENT DOCUMENT

The main purpose of the BRD is to Implement ERP for PLANT MAINTENANCE

OBJECTIVES TO BE ACHEIVED

preventive, repair, emergency and other user-defined maintenance tasks

Ensure all materials, supplies and parts are available and accessible to maintain and service

create new maintenance work orders from system to enhance communication

Complete maintenance history and audit trail

Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg

Spare inventory are consumed

Generate work orders and schedule material inventory and required labor (with associated skill

level) for planned maintenance

BRD, one can analyze all process. This document will help Management,

m to switch all system in ERP with required Reports.

PLANT MAINTENANCE & to incorporate all

defined maintenance tasks details.

Ensure all materials, supplies and parts are available and accessible to maintain and service

to enhance communication

Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg

material inventory and required labor (with associated skill

anagement,




2. BUSINESS OVERVIEW

In NBCL & NDL Maintenance team is following 4 kinds of maintenance process

1. Annual Maintenance (Through OEM)

equipments & will submit a report to Management with complete details of service need to be done

(Spare part details, Time to resolve

reports to Management and after required approvals maintenance team will make Purchase request for

spare parts if it is not available in Stores. After receiving Spare parts ,OEM person will come and resolve

the issue.

2. Preventive Maintenance- In this type of maintenance maintenance time /Date is fixed. Team will plan

accordingly.

3. Predictive Maintenance- In this type of maintenance ,team have to plan

machines.

4. Break Down Maintenance- This is a situation where team have to give support (Maintenance ) on

immediately.

All the above maintenance process are captured in manual sheets and then goes to management

preparing different reports. Only if OEM service person is comi

being raised. Rest all are in manual sheets.


PLANT MAINTENANCE

In NBCL & NDL Maintenance team is following 4 kinds of maintenance process-

1. Annual Maintenance (Through OEM)- In this process a service person will come to analyze the


(Spare part details, Time to resolve problem, Cost for resolving issue's). Maintenance team will send this



In this type of maintenance maintenance time /Date is fixed. Team will plan

In this type of maintenance ,team have to plan as per

This is a situation where team have to give support (Maintenance ) on

All the above maintenance process are captured in manual sheets and then goes to management

preparing different reports. Only if OEM service person is coming for service then only a service PO is

being raised. Rest all are in manual sheets.

-

In this process a service person will come to analyze the


issue's). Maintenance team will send this



In this type of maintenance maintenance time /Date is fixed. Team will plan

as per to working condition of

This is a situation where team have to give support (Maintenance ) on

All the above maintenance process are captured in manual sheets and then goes to management for

ng for service then only a service PO is




2.3 FLOW CHART OF PLANT MAINTENANCE

MAINTENANCE

ANNUAL

MAINTENANCE

PREVENTIVE

MAINTENANCE

PREDECTIVE

MAINTENANCE

BREAK DOWN

MAINTENANCE

In

Annual Maintenance process

service PO need to close after

Work Order close.


PLANT MAINTENANCE

PLANT MAINTENANCE-NBCL

STORE

WORK ORDER

PURCHASE

REQUEST

PO

MATERIAL

REVEIVED / GRN

Work Order In

Process

WORK ORDER

CLOSE

SERVICE PO TO

OEM

SERVICE PO

CLOSE

Spare part

availability

check at store

If

Yes If No




SUGGESTED FLOW IN ERP

STEP 1. ISSUE LOG (ANNUAL / PREVENTIVE

Whenever there will be some maintenance required , Maintenance team will have to

in system. This may be Annual maintenance / Preventive Maintenance / Predective Maintenance /

Breakdown Maintenance. This is a sample format to log problem

Abbreviations


PLANT MAINTENANCE

(ANNUAL / PREVENTIVE / PREDECTIVE / BREAKDOWN

Whenever there will be some maintenance required , Maintenance team will have to


Breakdown Maintenance. This is a sample format to log problem details with Machine.

DOWN - MAINTENANCE)

Whenever there will be some maintenance required , Maintenance team will have to create an Issue Log


details with Machine.




COMMON PROCESS FOR APPLICATION

User can perform following task.

a. Add: It is used to add new record.

b. Edit: It is used to modify existing record.

c. View: It is used to view in details.

d. Close: It is used to close the screen/form

e. Delete: It is used to delete existing record.

f. Save: This button updates the modified entries.

g. Cancel: It helps in cancelling the ongoing process.

h. Print: It prints the report.

CANCELLING THE EXISTING ISSUE

There may be some scenario where modification required on

to login from their id & can make changes as per to requirement ( Approval Required

Mandatory). To make any changes department have to take approval from Management ( Auto alert to

Supervisor login / request for change ) through ERP Only . This process will capture all history of making

Plan , Editing , Cancelling & Closing details.


PLANT MAINTENANCE

Add: It is used to add new record.

Edit: It is used to modify existing record.

View: It is used to view in details.

close the screen/form

Delete: It is used to delete existing record.

Save: This button updates the modified entries.

Cancel: It helps in cancelling the ongoing process.

SSUE LOG FROM SYSTEM / EDITING DETAILS FROM

There may be some scenario where modification required on loged data or cancelling the

to login from their id & can make changes as per to requirement ( Approval Required

atory). To make any changes department have to take approval from Management ( Auto alert to


Plan , Editing , Cancelling & Closing details.

ETAILS FROM SAVED LOG DATA

data or cancelling the log , user need

to login from their id & can make changes as per to requirement ( Approval Required- Management -

atory). To make any changes department have to take approval from Management ( Auto alert to





STEP 2: JOB ORDER/ CLOSING JO

After Making Maintenance Log

allocate the work in actual. User need to fill all details of

complete the Order.

*Once the JO is assigned to a supervisor through Work Order, System will show JO status as WIP &

Once Work order is completed , system will show JO status as Completed.


PLANT MAINTENANCE

JO

for Machines , User need to make JO ( Job order) where they will

allocate the work in actual. User need to fill all details of Shift / Machine / Spare Part


Once Work order is completed , system will show JO status as Completed.

, User need to make JO ( Job order) where they will

Spare Part Required Qty to





STEP 3: (MRS) MATERIAL REQUISITION

In this form User can request for materials required for

after Maintenance / Repairing the balance materials will be issued

user need to select codes for the same

Abbreviations


PLANT MAINTENANCE

EQUISITION SLIP

can request for materials required for Maintenance process. Material will be received &

the balance materials will be issued back to warehouse. For

the same.

. Material will be received &

to warehouse. For all Spare parts




STEP 4: MATERIAL RECEIVE NOTE

After getting materials from stores , user need to make " stock in" in

Maintenance team have to count all materials &

raised. Here they can enter the details like short fall in Qty while receiving materials from Stores

warehouse. This is very important for recording movements of each item through system.

mandatory here.

STEP 5: WORK ORDER / CLOSING

Here user need to allocate the work to respective supervisor along with the shift / Time required to

complete the JO. All spare parts will be handed over to supervisor to complete this work.

After completing Work Order , User need to change the status of WO to Close. This format will also be

used for closing Work Order in system.

all will be recorded in Machine Repair Logs. One can see in re


PLANT MAINTENANCE

OTE

After getting materials from stores , user need to make " stock in" in Maintenance

team have to count all materials & cross check before making inward entry against MRS

raised. Here they can enter the details like short fall in Qty while receiving materials from Stores

. This is very important for recording movements of each item through system.

LOSING WORK ORDER



leting Work Order , User need to change the status of WO to Close. This format will also be

used for closing Work Order in system. When User will close the WO , the linked JO will be closed and

all will be recorded in Machine Repair Logs. One can see in reports - All history of the machines like No .

Maintenance warehouse .

cross check before making inward entry against MRS

raised. Here they can enter the details like short fall in Qty while receiving materials from Stores /

. This is very important for recording movements of each item through system. QC is



leting Work Order , User need to change the status of WO to Close. This format will also be

When User will close the WO , the linked JO will be closed and

All history of the machines like No .




of time it has been repaired / Day Wise / Supervisor Allocated / Time taken to repair / Type of

maintenance etc.

Over All Equipment Efficiency Report

There will be a report to calculate OEE (Over all Equipment

The table below contains hypothetical shift data, to be used for a complete OEE calculation, starting with

the calculation of the OEE Factors of

of measurement (in this case minutes and

Example-

Calculation steps-

As per to above example , system will calculate Planned Production Time, Good Bottles

Availability & finally Quality. Below formula defined for each steps.

Result-


PLANT MAINTENANCE


Over All Equipment Efficiency Report

There will be a report to calculate OEE (Over all Equipment efficiency ) during a shift.


the calculation of the OEE Factors of Availability, Performance and Quality. Note that the same units

of measurement (in this case minutes and Bottles) are consistently used throughout the calculations.

As per to above example , system will calculate Planned Production Time, Good Bottles

Availability & finally Quality. Below formula defined for each steps.


efficiency ) during a shift.


. Note that the same units

) are consistently used throughout the calculations.

As per to above example , system will calculate Planned Production Time, Good Bottles, Operating Time,




APPENDIX A: REQUIREMENTS ANALYSI

The undersigned acknowledge that they have reviewed this requirements analysis document and agree

with its information. Changes to this version will be coordinated with, and approved by, the undersigned,

or their designated representatives.

Signature:

Print Name:

Title:

Role:

Signature:

Print Name:

Title:

Role:

Signature:

Print Name:

Title:

Role:


PLANT MAINTENANCE

REQUIREMENTS ANALYSIS APPROVAL

acknowledge that they have reviewed this requirements analysis document and agree


or their designated representatives.

Date:

Date:

Date:

acknowledge that they have reviewed this requirements analysis document and agree


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