Jump to content
Test ×
Hadwll

Implementing SAP from basic excel

Recommended Posts

I am going to be using this space to document our transition and implementation to SAP.

I will share what I can and provide as much info for people reading and also for your comments. To say I have been thrown in at the deep end would be about right but it is all good. I am lucky to be able to have this experience on my CV.

The story so far; we are part of a multinational company that has SAP on their sites in the US and are now rolling it out to UK sites. The project stared in the middle of this month and is expected to wrap up around October.

Our site has a couple of challenges, very little CMMS, outdated inventory and no site designated planner. However, the need for one has been recognised as vital and is expected over the next couple of months.

My role presently is as an engineering manager, I am heading up this SAP project on our site and have begun to populate the master data file. This coming week we have set about employing a resource to begin to put every item in the engineering stores onto an excel sheet for the load. it is my responisibility to generate the workcenters, locations and equipment lists for the masterdata. We have a few weeks to get this compiled which is no mean feat when no legacy system exists. 

I have a question on functional locations, is it better to be broad and abstract, and have fewer locations. Or be more specefic and have more locations?

My thinking is too many locations will prove difficult to maintain, but then too few may make searching difficut?

Having not used SAP before in any real capacity it would be good to get some thoughts.

 

 

 

 

 

 

 

Share this post


Link to post
Share on other sites

Hi @Hadwll,

That is a really good experience and will definitely add a lot to you CV. It is quite rare to find people who have gone through this situation.

I haven't implemented SAP anywhere, but I led a project that aimed at creating a standard system for different plants (standard FLOCs, equipment, BOMs, Datasheets, criticality and maintenance plans), which is not that exciting, but tought me a lot.

You do have a challenge ahead, especially because you said you have just a few weeks. This sort of project requires a lot of attention to details, so try to plan every single step to ensure you will be able to meet your deadline with a high quality work. For instance, one single typo might be enough for a few hours of downtime as you could be buying the wrong part due to this typo, especially when you are creating the bill of materials for hundreds of pieces of equipment.

In regards to the functional locations, I recommend using a detailed hierarchy. Try to use different levels when creating your FLOCs (Site-Process-Subprocess-Equipment Tag), this might mean more work now, but can save you a lot of time in the future when analysing improvement opportunities. There is a standard for this topic, but I cant remember now. I will have a look here to see what I can find.

Also, if you allow me to suggest something, try to have a diverse team working with you. For instance, get people who really experienced on your plant that will have information about the pieces of equipment or where to find the information required, and people really good with this master data thing and spreadsheets. Those two sort of professionals working together will definitely be able to speed up and provide quality to your project.

I do like this topic and I am looking forward to reading more about your experience.


Regards,

Raul Martins

Share this post


Link to post
Share on other sites

Hi @Raul Martins,

For sure I am glad to be part of the project. The external SAP team has requested a functional hierarchy like you say, in the form 4-2-5-16

4- site code

2-workcentre

3-location

16-description

 

We are picking a numbering system for the equipment presently, each piece of equipment will have a nameplate welded onto the frame that will be easily found in SAP.

if anyone has thoughts, we are thinking we will go with the following configuration.

site-workcentre-equipment type- equipment number 

so an example number may be

CF34-2P-CP-002

Site-2nd process-centrifugal pump-002

We have an excel wiz onboard and a number of the shift technicians are in on the act as well. I think we all agree the importance of quality when it comes to having the responsibility of setting up this system.

The count of the inventory has started this will be a much larger ongoing task, but it has begun. Apart from that, yesterday was spent entering more equipment and functional locations into the MasterData.

Share this post


Link to post
Share on other sites

Hadwll,

Good morning and thanks for sharing your journey! I am very interested in reviewing your progress and results.

Have a great day!

Jim

  • Like 1

Share this post


Link to post
Share on other sites

Hi @Hadwll,

On ‎6‎/‎2‎/‎2020 at 2:20 PM, Hadwll said:

CF34-2P-CP-002

Site-2nd process-centrifugal pump-002

I think that is fine.

Also try to create detalied descriptions for those funtional locations. For instance:

CF34-2P-CP-002 - Raw water pump from tank A to tank B

 

This is really handy when doing failure analysis and understanding the process of your plant.


Regards,

Raul Martins

  • Thanks 1

Share this post


Link to post
Share on other sites

Short update. 

Work centers are complete and the cost centers have been assigned by the site accountant. 

I gave a short presentation to the team introducing SAP, what a work centre is, functional location and the reason for the equipment lists. 

This was as much for me to be 100% clear and be able to give a good explanation. 

I created a CAD drawing of the site showing the work centers that I will plot out A1 for the techs and the planner. Same with the functional locations to follow. 

This will greatly assist the technicians if they are creating work orders for breakdowns, so I am being told. 

We have about 10 days left to get the functional locations and equipment lists compiled. Not coming from a legacy system means we are going to be busy.

We altered the machinery number slightly to remove the site code and introduce a line ID. 

It is now. 

2P-LN1-CYR-001

Process 2 line 1 conveyor number 1.

Reasoning being for the technicians searching will should be able to remember the line when they get back to the workstation and can pick the item of equipment from there. We are being guided by a sister site who have implemented the system, this is their advice and we are glad of it. 

 

  • Like 1

Share this post


Link to post
Share on other sites

Hi @Hadwll,

It has been really interesting to read your posts.

In regards to the new FLOC structure, if your site has no interaction and there is no plans at all to have this interaction with other sites, then the site code is not necessary.

Yet, if they plan to have one system for all of the sites, then I recommend using the site code and add the line ID. This would result in 5 levels on your structure, which is something very common in many companies.

 

Kind regards,

Raul Martins

Share this post


Link to post
Share on other sites

Great insight @Raul Martins thank-you.

Checking in again on the project.

We have completed the Work Centres (WC) and FLOC  and are working our way through the equipment.  We are drawing information from many places, for example we had a pump survey completed a few years ago which details all the makes and models of every pump in the plant, this info will be invaluable once I have updated.

I met with the insurance inspector today as he has an asset list of all the pressurised vessels, boilers, compressors etc. It will speed me up in compiling the list. We had a discussion on how we will be able to schedule the inspections into the PM plan.

The other sites we are working with are struggling with resources  for compiling the master data. A number of the guys are trying to do their normal job, so things have been pushed out abit. As such we have endeavoured to have the equipment list completed by the end of this week and then we are going to begin to add the task lists.

The second part of our task is to get all of the spare parts that are in the engineering store onto excel for upoad, luckly I have good help with this side of the project we are taking this time to grade each spare part as below. ( I cannot take credit for this system, one of our equipment suppliers grades their parts this way)

A- Consumable (parts that are used weekly by the machine in normal service)

B- Breakdown part (if this part becomes broke on the machine it results in line downtime or the process is severly impacted)

C- minor overhaul part (parts typically reduired during minor overhaul >1year)

D- major overhaul part (required for major overhaul <1 year)

E- parts that have been  required to be replaced after an inspection historically,

By this logic we should always have A and B parts instock to ensure that we are well covered during normal production. C, D and E I am thinking we can maintain stock for the common items and order the remainder for upcoming services. 

Please let me know what you guys think.

 

 

 

 

 

 

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

×
×
  • Create New...

Important Information

By using this site, you agree to our Terms of Use, Privacy Policy and use of We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue..