The Challenge
A global energy company used Maximo as its Enterprise Asset Management (EAM) solution for all work management activities related to its maintenance operations with integration to SAP for Inventory and Material Management. They migrated from Maximo to standard SAP PM out-of-the-box functionality, but gaps in the migration impacted effective and efficient maintenance execution, such as:
- Improper hierarchy structure.
- Generic maintenance plans (MPs) that were not fit for purpose.
- Duplicate MPs were generated.
- Tasks were created that did not apply to existing equipment and process configurations.
- Maintenance tasks did not appropriately support the current equipment configuration.
- Mass Uploads were created with misaligned MP object lists.
The Solution
The company initiated a Maintenance Build project with Sullexis to mitigate the gaps. Our team leveraged Maximo’s location and asset data to mitigate the misalignment of the hierarchy and align with the ‘To Be’ business requirement. Our team worked with our client’s engineers to validate the hierarchy structure for proper parent-child relationships, system criticality, and equipment code classification.
Sullexis managed the data through a data governance and quality assurance process of enrichment, cleansing, and validation to achieve an accurate and complete data set. The project team loaded the data to SAP PM for Hierarchy, Locations, Assets, Maintenance Plans, Equipment Criticality, and BoMs.
The Result
All equipment records for Locations and Assets were loaded into SAP PM with fully enriched data. With data fully aligned with the ‘To Be’ design and loaded to SAP, our client achieved the following:
- Improved the efficiency of maintenance execution through enriched maintenance plans (MPs).
- Ensured accurate and complete BoMs with corrected item masters.
- Improved execution metrics and asset reliability with enriched and accurate MPs.
- Improved availability of spare parts in systems and ensured alignment of BoMs with applicable MPs.
- Aligned MPs and BoMs to OEM recommendations and equipment maintenance histories.
- Reduced errors in materials orders through updated and corrected Item masters.
- Corrected BoMs to align with existing equipment configurations.
- Created consistency in MPs and BoMs of identical equipment.
- A foundation to improve reliability and optimize spare parts inventory.