erp plant maintenance doubt clearing drive report
TRANSCRIPT
ERP Plant Maintenance Doubt Clearing Drive From 4th May 2012 to 16th June 2012
Vishal J. Waghchaure, Deputy Executive Engineer
ERP PM Core Team— Corporate Office
T: 0 810 810 6238 E: [email protected]
A Comprehensive Analysis of the Necessity & Effect of
ERP Plant Maintenance Doubt Clearing Drive | 2
Executive Summary As a part of ERP implementation, Plant Maintenance notifications have been released since 1
st July 2011. Punching these
notifications in the ERP system is an imperative task as the System Availability Report is based on these notifications.
Also, correct data in respect of all the system elements form a crucial part of ERP. Keeping this in view, Zonal Plant Maintenance Champions are given with the authorization to update the Equipment Master Data. As certified by these Zonal PM Champions, the Master Data has been updated in the system till 31
th March 2012 and any changes thereafter are being
effected in the system immediately in coordination with ERP PM Core Team.
It is observed that PM End Users at various levels are not creating / monitoring correct IR and BD notifications in the system leading to generation of incorrect System Availability Report and defeating the very purpose of ERP PM implementation.
Keeping this in view, a special drive has been taken by Mr. Vishal Waghchaure, Dy.E.E. for clearing all the doubts / issues faced by the PM End Users across all the zones up to Division level. During this drive, personal interaction has been carried out with by him with every individual PM End User i.e. Division Head, all substation in-charges & engineers working in Line Maintenance, O&M Division and Circle Office.
TABLE OF CONTENTS
Executive Summery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Factors behind carrying out this drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Methodology & Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Salient features of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Outcome – The Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Statistical facts
Issues faced by End-users
Responsibilities & Limitations of PM Core Team
Responsibilities & Limitations of PM Zonal Champions
Countermeasures & Suggestions from field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The way ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ERP PM END USER QUESTIONNAIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANNEXURE - I
ERP Plant Maintenance Doubt Clearing Drive | 3
Factors behind carrying out this drive
Vast Information Gap between Corporate Office & End-users
Sluggishness in response on the part of end-users
Ignorance about the basic concepts in ERP & Legacy System too
Ambiguity regarding individual roles to be played
Entry of new engineers in O&M wing by virtue of transfers, promotions & new recruitments
Significant intensification in individual responsibilities
Major threat to the investment on the project in case of poor performance by end-users
Elucidating the basic methodology
Visit to EVERY EHV O&M and RS Division through all the Zones
PERSONAL INTERACTION WITH EACH & EVERY PARTICIPANT
Clearing all the Technical / Non-technical doubts
Giving a comprehensive outlook of ERP in general and Plant Maintenance module in specific
Distribution of Soft Copies of Important Manuals, Presentations & Circulars
Getting a Questionnaire filled up from every participant
Exhaustive analysis of the filled Questionnaires at Corporate Office
Formulation of strategic training plan based on this analysis
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Schedule for the drive
Date Zone Offices Covered No. of Participants
4-May-12 Nagpur
EHV O&M Division Ballarsha / Vardha HVDC TL O&M Division Chandrapur HVDC Indoor Division Chandrapur 400KV RS Division Chandrapur
50
5-May-12 Nagpur EHV O&M Division Nagpur / Bhandara RS Urban Division Nagpur 400KV RS Division Koradi / Khaparkheda
43
8-May-12 Aurangabad EHV O&M Division Parbhani 16
9-May-12 Aurangabad EHV O&M Division Nanded 15
10-May-12 Aurangabad EHV O&M Division Latur 400KV RS Division Girwali
23
11-May-12 Aurangabad EHV O&M Division Beed 17
15-May-12 Aurangabad EHV O&M Division Aurangabad 400KV RS Division Waluj
29
16-May-12 Pune EHV O&M Division Pune 400KV RS Division Lonikand -II RS Division Pune
28
17-May-12 Pune EHV O&M Division Solapur 400KV RS Division Lamboti
29
18-May-12 Pune EHV O&M Division Baramati 14
19-May-12 Pune 400KV RS Division Lonikand -I / Jejuri / Chakan 31
21-May-12 Nasik EHV O&M Division Babhleshwar 400KV RS Division Babhleshwar
20
22-May-12 Nasik EHV O&M Division Nasik 28
23-May-12 Nasik EHV O&M Division Dhule 400KV RS Division Dhule
28
24-May-12 Nasik EHV O&M Division Jalgaon 400KV RS Division Khadka
30
28-May-12 Amravati EHV O&M Division Amravati 29
29-May-12 Amravati EHV O&M Division Akola 400KV RS Division Akola
34
4-Jun-12 Vashi EHV O&M Division Kalwa / Bhandup 23
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5-Jun-12 Vashi EHV O&M Division Boisar 400KV RS Division Kalwa / Padghe
12
6-Jun-12 Vashi EHV O&M Division Panvel 400KV RS Division Kharghar
17
7-Jun-12 Vashi EHV O&M Division Dombiwali / Mahad 400KV RS Division Nagothane
18
14-Jun-12 Karad EHV O&M Division Kolhapur 400KV RS Division Telandge
39
15-Jun-12 Karad EHV O&M Division Ratnagiri 15
13-Jun-12 Karad EHV O&M Division Karad 400KV RS Division Karad / New Koyna
22
16-Jun-12 Karad EHV O&M Division Sangli 19
Total Participants 629
Salient features of the drive
Time Span: 4th May 2012 to 16th June 2012
Total Sessions Held: 25
Total Number of Offices Covered: 53
Total Number of Individual Interactions: 629
Approximate amount saved: Rs. 9, 50,000 /- ( Expenditure of Rs.1500/- per participant had they been
called at Mumbai like for all other drives )
Average increase in notification creation: 176%
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Outcome – The Effect % Increase in Notification Creation after the drive :
Parameter
Before
After
Amravati Aurangabad Karad Nagpur Nasik Pune Vashi
Awareness about Availability Calculations < 2% < 2% < 2% < 2% < 2% < 2% < 2% 100%
Awareness about Availability Circular
58% 49% 62% 66% 78% 48% 67% 100%
Awareness about PM End User Document
44% 48% 43% 44% 57% 66% 64% 100%
Awareness about Zonal IT Engineer
91% 53% 73% 52% 46% 73% 53% 100%
Knowledge of checking Equipment & Line Details in SAP
71% 68% 65% 61% 75% 76% 69% 100%
Awareness about BASIS Reference Manual
< 5% < 5% < 5% < 5% < 5% < 5% < 5% 100%
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Introspection
Statistical Facts
Although 75% Users have checked data in the system, only 31% users have updated the data till date.
Rest 44% Users are still lagging.
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Although 65% Users have already created notifications in the system, only 23% users have created 100% notifications.
Rest 42% Users are still lagging.
33% Users have not obtained any ERP Training till date.
Reasons for the same are:
1. Recruitment of new engineers
2. Migration to O&M wing by virtue of Transfers
3. Migration to O&M wing by virtue of Promotions
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Issues faced by End Users
Responsibilities & Limitations of Core Team
Responsibilities:
Co-ordination with Process owner & IBM consultants
Co-ordination with all the zonal champions & imparting training to them
System Configuration & New developments
Technical support to more than 600 PM end users
Equipment Master Data Update
Functional Location Master Data Update
Work Center Master Data Update
Task List master Data Update
Authorization Group Master Data Update
Planner Group Master Data Update
Following are the prominent issues faced by
End-Users while operating the system:
1. Slow speed of connectivity especially
at V-SAT Locations
2. Unstable link
3. Authorization Issues
4. Unavailability of Connectivity & PC at
new substations
5. Inadequate training
6. Antivirus Issue
7. Dearth of monitoring from higher offices
8. Motivation & Moral Support
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Limitations:
Lack of Certification Training leading to incomprehensive approach to work and complete
dependency on the consultants
Insufficient members in PM Core Team
Difficulty in carrying out daily works due to impermanent sitting arrangement
Responsibilities & Limitations of Zonal Champion Team
Responsibilities:
Co-ordination with PM Core Team
Providing support to all the zonal End-Users
Imparting training to End-Users
Collecting data from the field & cleaning it as per system requirements
Overall monitoring of PM module activities across the respective zone
Limitations:
In wake of their engrossment in routine duties Zonal Champions are not able to dedicate
themselves fully to ERP work leading to added response time
Difficulty in carrying out the assigned tasks due to lacking support from administrative offices
Lethargic response from end users due to absence of administrative enforcement
Deprivation of incentives of any kind to carry out such exasperating efforts
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Countermeasures & Suggestions from field
All the substation in-charges should keep their data updated in the system at any given time
Creation of Notifications by concerned substation in-charge for each & every interruption on substation
equipment / line
Enforcement by administrative offices for creating notifications
Strict monitoring of Master Data & Notification Creation at all levels to ensure their correctness
Zonal PM Champions should be relieved if engaged in other duties & should be mobilized up to Division
Level
Periodic training programs for end-users by Zonal champions
In addition to Zonal PM Champion, assigning Champions at Circle and Division level also
Allowing alternate means of connectivity where Tulip link is not provided or very slow
Enforcing exclusive usage of Mahatransco E-mail IDs for all official communications
Increasing mail box capacity to widen its usage
Getting the actual speed of connectivity checked where Tulip link is UP but very slow
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The way ahead
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ANNEXURE - I
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