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Each equipment will be created as individual route standard job and combine them Route pm under one route.
Eg. Route ID: 64 IG System 12 M maintenance
Route Description : Main tech acc for route pm will be used in route id description.
When creating route,the route pms in the same group should have the same dates on all PM actions.
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Prerequisite: The standard jobs to be used in route standard jobs should exist as route standard jobs in IFS.
5.4
Scenarios5.4.1
(
Automatic Generation of work orders based on lead time and created work orders will be released)5.4.2 Advance creation of work orders for PM actions when there is opportunity 5.4.3 Revise PM Action (adjust interval etc.)
5.4.4 Revise PM action from revised standard job
5.4.5 Create WO for running hour based PM Action, when the PM is due
5.4.6 Create work order for running hour based PM action when there is opportunity. (The next work order should be reset based on last finished date)
5.4.7 Replacement for PM Actions (sequencing) for calendar based PM actions 5.4.8 Replacement for PM Actions (sequencing) for running hour based PM actions 5.4.9 Revised PM action from generic standard job
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5.5
PM Action fieldsIFS Field BWO description of Field
PM No PM Number
Work Description PM Description (long)
Site Facility
PM Action status Status
Object Id Equipment Tag
Action Job Type & Job class combination (e.g. Inspection, Cleaning, Ma.Sa)
?? Lead Time (Days) for Automatic WO generation before set due date
Route PM Action Route
Standard Job Job Plan
Work Type Work Type (SCPM, PM)
Last Performed Last Start Date
Maintenance Plan ->Actual Finish Last Completion Date Maintenance Plan ->Planned Date Earliest Next Due Date Calculated Pl Start Estimated Next Due Date
Main.t Org. Department Responsible
Interval Frequency
Interval Unit Frequency Unit
Test Point & Parameter Meter
PM Criteria-> Interval Meter Frequency
Remaining Hours Units to Go
?? Generate WO Ahead By
Performed Date based Use Last WO's finish Information to calculate Next Due Frequency Condition Generation Generate WO Based on Meter Reading (Do Not Estimate)
PM Replacements. Job Plan Sequencing
PM connections PM Hierarchy
Test Number Reference
5.6 Additional Configurations in IFS 5.7 User Roles
Role Activity IFS
PM Administrator Create/Revise PM Actions
(Route and Separate) Full Access Maintenance Sup. PM Actions (Route and Separate) View Access
Create work orders from PM (Calendar and condition generation)
Full Access
Offshore Technician PM Actions (Route and Separate) View Access
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6. Work Order
The Work Order module contains all relevant information required for work to be planned, delegated, distributed and performed. A work order can either be automatically generated by the system based on a pre-determined preventative maintenance schedule, or it can be manually created by the user on an adhoc basis, for corrective, breakdown or modification work.
Below is the current Work order Priorities and the Shutdown codes and how they influence the window for completion. A workable solution to be found for these very complex items as it is in Maximo. Although the one in Star is straight forward we need to be able to have a prioritization regime however it needs to be simplified.
Work Priority:
Priority 1 – Work order shall be completed within 7 days from planned start date for PMs and Creation date for other manual work orders
Priority 2 – Work order shall be completed within 14 days from scheduled start date for PMs and Creation date for other manual work orders
Priority 3 – Work order shall be completed within 90 days from scheduled start date for PMs and Creation date for other manual work orders
Priority 4 – Work order shall be completed within a planned period not more than 360 days from scheduled start date – [To be reassessed together with shutdown codes.]
Operational status (Shutdown Code):
For PM based work orders, the priorities an operational status will be defaulted from PM actions.
The Work Order Processing contains the following steps:
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A work order can be created in several ways manual work orders for CM, BDM or MOD or PM generated work order via calendar or running hours.
When planning and preparing a work order, first enter some optional general information such as the work type, the work priority, the operational status. In case of work order generated from PM Action, these information are defaulted from PM actions.
The planned start and planned finish of work orders are defaulted based on work priority.
Planned finish of work orders are defaulted based on work priority.
Materials:
The materials required for the job are created in material requisitions for the work order. The inventory part availability can be found on the material requisition line. The required part can be reserved for the work order.
If the required material not available in inventory, a purchase requisition can be created from material requisition. The requisition will then be turned into a RFQ and purchase order
Operations (Crafts):
The required operations for the work order are defined under Operations. The crafts (internal, roving team, External crafts (class surveyor etc.) needed for each operations are defined with number of men required and the duration. The detailed operation description can be defined in Remarks for each operation.
Requisition:
In case of services require from external parties or material required which are stored in
inventory, a requisition can be created on the work order. The authorized PR will be processed by procurement. Refer PR section for information on PR flow.
Tools:
If the work requires specific tools or facilities, the can also pre-plan a separate work order with that information.
Jobs:
In case of CM, BDM work orders, if there is possibility to plan the work order based standard jobs.The standard jobs can be connected to work order.
To simplify the planning of a well-known work it is possible to use the separate standard job, which works as an aid. When a separate standard job is available with suitable operations for the work order,the separate standard job can be with the pre-selected values on material, tools and facilities and operations, to simplify the administration.
Project Activity:
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Pre-posting:
6.2 Execute Work Order
The prepared work orders are released by Maintenance Superintendent for executing the job. The work order is printed out.
The materials on the work order are issued by Material coordinator against the work order material requisition.
The technician collects the materials physically and executes the job. When the work is started, the work order status is set to ‘Started’.
In case of additional materials identified during the execution, the same are to be added in material requisition. Upon approval from Maintenance superintendent, the materials are issued.
After completion of work the work order is reported by the technician and the work order status is set to
‘work done’
Free Notes:
The additional comments related to the work can be entered in free note. The changes are logged for reference.
6.3 Report in Work Order
The completed work orders reported back into IFS by technicians.
The actual work done details, failure class, problem remedy, cause reporting, actual start and actual finish dates are updated on the work orders.
Time Report:
The technicians will report actual work hours in work order Time report against each craft.
Failure reporting:
After reporting in work order, the technical will set the status of the work order to “Reported’ for the Maintenance Superintendent to authorize and finish the work order.
Posting Authorization:
The reported work orders shall be authorized for the time reporting and reporting information by Maintenance Superintendent.
After validating the work order information, the work order status will be set to status “Finished”.
Historical work order:
The Finished work orders will be moved to historical work orders for further reference. The
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6.4 Route work order 6.4.1 Prepare route work order
The route work order is always PM (Preventive Maintenance) – generated. The route work orders for multiple equipment. For example have a route that has to be done with five involved objects, the system does not give a calculation of how much each and every action costs. The system adds up the total sum for the action.
When a route work order has been created, the user can continue preparing the work order. Some information is automatically filled in at generation. If material is needed for the work but do not have it in the inventory, make a requisition. The work instruction will be automatically available on work order based connected standard jobs.
6.4.2 Execute Route Work Order
The prepared route work orders are released by Maintenance Superintendent for executing the job. The work order is printed out.
The materials on the work order are issued by Material coordinator against the work order material requisition.
The technician collects the materials physically and executes the job. When the work is started, the work order status is set to ‘Started’.
In case of additional materials identified during the execution, the same are to be added in material requisition. Upon approval from Maintenance superintendent, the materials are issued.
After completion of work the work order is reported by the technician and the work order status is set to
‘work done’
6.4.3 Report in route work order
After the work is completed, the work order is to be reported in. A route work order has a simplified reporting in process. Before concluding work order, simply specify for each action in the route whether or not it was performed, enter Alarm Test results then report in the entire route. on route work order must also be completed and the actual finish date must be given.
During execution of a scheduled maintenance it is possible that a fault or function test failed which is discovered, which needs to be corrected in the ongoing work scope.For such cases,a corrective work order will be created for the object from route work order.
When you have filled in all necessary information, and have completed the work, change the status to 'Finished' to conclude the work order. As the result, the work order becomes historical, and could be used for information purposes only.
6.5
Scenarios6.5.1 Manually created work orders for Unplanned Maintenance (CM, BDM)
6.5.2Work orders from planned maintenance (Separate PM Actions)
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6.5.5 Work order with materials
6.5.6 Work order with Purchase requisition - Vendor Call off 6.5.7 Work order with Purchase Requisition - Equipment Services
6.6 Work Order Fields
IFS Field Field Description
WO No (Running numbers) Work Order Number-Unique
Work Order Identifier
Work type Work Type
Work directive Work Order Short
Description
Status Status
Work Order Journal Tab Status date
Object ID Equipment Tag
1. Project connection to connect WBS (Project activity) code
Project Type
2. Custom field (Operation, Sailing, Pre-sailing, Docking,
De-commissioning etc.)
Action Job Class
Custom Field (Predictive, Preventive. First Line etc.) Job Type
Action,Std. Job id Class-related reference
Maint. Orgn. Department
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Execution Time Duration
Qty On hand Mat in Stock
Wanted Receipt date Est. Delivery
PM description Interval Type
Interval Length
Operation description and Remarks Task Description (Long)
Crafts in Operations, Materials and document attachments in work order Report Connections
Work Done (Route and Separate) History ( Details of work
done)
Separate work order –Report In Tab-Class, Type, Performed action and Cause. Failure Reporting Free Notes (History log to be enabled for time stamp and user) Change Log
Same as change log Comments
Work order structure Parent WO
Purchase requisition no in Requisition tab on work order PR number
Posting control-Preposting GL-Account
Separate work order –Report In Tab-Class, Type, Performed action and Cause. Problem code
Custom Field (Mandatory based on work type +MOD) MOC Number
Document Attachment Attachment
Operational Status Shutdown Code
Custom field Info. From Functional object Risk Assessment
Reported by Raised By
Reported by Reported By
Entry date Reported Date
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PM- Action field Preservation
work order
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6.7 Additional Configurations in IFS 6.7.1 History log on free notes
6.7.2 History log on planned start and planned finish dates 6.7.3 Object Connection Transformation- WO-PR to RFQ line.
6.7.4 Custom fields
o Alarm test – on Route work order o Priority on WO_PR header
o Required Start date on Route work order o RBI Risk factor
o Project Type?
6.7.5 Rename Fault Desc. To TQ/MOC/Deviation Request 6.8 User Roles
Role Activity IFS
Planner - Prepare work order
- Report In work order - Single Screen work order - Report In Route
Work Order Status (All) -(Route and Separate)
Full Access
Maintenance Sup. - Prepare work order - Report In work order - Single Screen work order - Report In Route
- Work Order Status (All) (Route and Separate)
Full Access
Offshore Technician - Report In work order - Report in Route
- Work order Status (Started, Work Done, Reported) (Route and Separate)
Edit Access
- Prepare work order View Access
7. Offshore Planning & Scheduling Process Flow
The IFS System must be able to support the BWO offshore planning and scheduling processes. These process flows will also form the basis of defining user roles and responsibilities, and access rights within the CMMS.
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7.1.2 3-Monthly
7.1.3 1-Weekly
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8. Inventory Parts (Spare Parts & Consumables)
The Inventory module contains all relevant information related to equipment spare parts and consumables used in the operation and maintenance of the offshore facility. Unique material numbers are used in the development of equipment bill of materials lists, purchasing and re-ordering materials, receiving of delivered materials, and the managing of inventory.
The unique material number exclusively identifies a specific spare part, and applies across the BWO fleet, so as to enable spare parts interchangeability between equipment and a common inventory database for all facilities where applicable.
Materials must be able to be classified according to the proposed classification structure, and must also be able to be rated by criticality (SC, H, M, L) so as to enable critical stock safety levels to be defined and monitored.
8.1 Inventory Parts 8.1.1 Master Part
The parts created in IFS are unique part number that identifies the same part in all facilities. This gives the flexibility of verifying stock of the same part number in different facilities. The inventory part codification follow BWO Material Codification Procedure (Document No…..).
In case of new parts to be added for a facility,the part availability is verified against the master part list .If the part is available in master part,the same part will be created as Inventory in the facility site.
In case of non-availability of master part,a master part is created and the same is crerated as Inventoriy part in the requesting site.
Part Catalog:
The Master part catalog allows to:
Get an overview of all registered parts.
Define part manufactures and manufacturer part number
Define Alternate parts
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8.1.2 Inventory Parts per Facility
Inventory Part General Information:
Attachments MSDS/PDS Inventory Part – Cost:
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Inventory Part – Planning Data:
Inventory Part –Default Location (in the facility):
Inventory Part - Characteristics:
Inventory Part Availability Planning:
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8.2 Inventory Part –Scenarios
8.2.1 Create new part which does not exist in the system 8.2.2 Update part information
8.2.3 Extend a part to facility from master part 8.2.4 Deactivate Obsolete Part number
8.3 Inventory Part Fields
IFS Field BWO Description of Field
General Tab
Site Facility
Inventory part no Material Number
Old Part Number BWO Old number (Number from Star/Maximo) Part Description in use Material Description
Inventory Part: Inventory
UOM Issue Unit
Certificate needed Certificate requirements for the part
Criticality Criticality 1,2,3,4 (SC,H,M,L)
Modified Last updated date
Commodity group 1 Commodity group
Product Family Component category
Product code Spare part code/consumable/tools Acc. Group
Planning Data
Safety stock Minimum level
Order point re-order Point
Lot Size Quantity to Re-order (Maximum level)
Cost -Tab
Cost Standard Cost/Average cost/Last purchase cost
Part Catalog
Master Part:Info Text Long Description Part Manufacturer No Maker/Manufacturer
Manufacturer's Part No Maker's/Manufactuer's part number
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8.4 Additional Configurations in IFS 8.4.1 Custom Fields
1. Certificate Needed 2. Criticality
8.5 Inventory Part Basic Data 8.5.1 Product code
8.5.2 Product family 8.5.3 Commodity Group 1 8.5.4 Accounting Group 8.6 User Roles
Role Activity IFS
Master Part Administrator Create new Master Part
Create new Inventory part for facilities
Full Access Material Coordinator Update Inventory part information for
the Site
Create new Inventory parts?
Edit Access
Maintenance Sup Master Part Inventory Part
View Access Offshore Technician Master Part
Inventory Part
View Access
9. Inventory Management
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9.1 Inventory – Locations (Stores)
The Inventory locations that store materials for a facility can be of the following
1. The storage locations/store rooms on board the vessel – The issue of material to work orders and material requisitions happen from this location
2. Onshore Store location – Intermediate storage for the Vessel to keep additional stock
3. Consolidated warehouse / Freight forwarder arrival location - PO materials are received into this location for the freight forwarder to transport the materials to the vessel. The invoice is processed based on receipts made in this arrival location.
All the storage locations are defined as Locations in IFS to track the materials. The location type for 1 &2 is
‘Picking’ and for 3, it is Arrival.
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Material requisitions are used when internal demands for chemicals from production, Personal protective clothing, Tools etc. can be fulfilled by issuing goods from inventory.
9.2.1 Scenarios
9.2.1.1 Material Issue for Production/.
9.2.1.2 Material issue for Consumables/
9.2.1.3 Material issue against maintenance job (through work order)
9.3 Inventory Counting 9.3.1 Scenarios
9.3.2 Count per location for a site
9.3.3 Count based part number series (set of parts)
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9.3.4 Count per part
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