Avantis Serialized Inventory and Repairable Spares

2. Avantis Serialized Inventory and Repairable Spares Session Name: Functional Workshop/Training Part 1 Session ID #: PBAV113-2 Presented by Morag Walsh 11/08/11 Invensys proprietary & confidential

3. Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform

4. Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Asset Performance Performance Measurement and Reporting Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control Automation Software Applications DCS PAC SCADA HMI Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers

5. Avantis.PROSerialized Inventory & Repairable Spares

6. Why serialize? • Collect specific history or location information about items without statistics or Preventive Maintenance • Manage spares out of the storeroom, but also track costs and/or statistics related to that spare • Track location of parts • Build entities from a work order and return to inventory for later user. • Constructed assemblies can be tracked similar to inventory

7. Detail Levels for parts Least Detail Most Detail Serialized Inventory Inventory Entity Repairable Spares

8. Serialized Inventory • Ability to track inventory items on specific unit basis • Each unit uniquely identified • Tracks location of discrete units • Serialized item • any item that has been assigned a serial number • Types of serialized items • General serialized items • Trackable assets

9. Serialized Inventory • Serialized items can also be designated as trackable assets • Allows specific unit identification and tracking • Movement and Costs tracked for each discrete unit • Item set up as entity as well as inventory item

10. Serialized Inventory Trackable Assets (Entities) • Inventory information available if serialized item linked to entity

11. Item Type Value List Indicate if items of this type are serialized Inventory Classification Value List Identify classifications requiring serial numbers Define whether serialization is mandatory for classification Assign whether AUC should be updated for items in this classification MRO Item General Information Identify item as serialized Indicate whether item is repairable Define serialization UofM Setting up Serialized Inventory

12. Item Type Value List Serialized Items tab Designates whether: Serialization is allowed Item must be serialized when received Asset (entity) can be created Setting up Serialized Inventory

13. Inventory Classification Value List Identify if Serial numbers required for items in this classification EAR used to move item to or from classification EAR transaction can assign a new parent for the trackable asset. Allows classification to be excluded in AUC calculation Setting up Serialized Inventory New tab

14. Setting up Serialized Inventory MRO Item set up • Specify that the item will be serialized • Specify the unit at which to serialize • must be equal to or lower than item’s unit of measure

15. Recording Serial Numbers • Serial numbers can be recorded from: • Item Serialization Worksheet • MRO Item • Work Order Resource Requirement • Inventory transactions • Receipt Worksheet • Serial numbers cannot be recorded from MRO Item Setup Wizard

16. Recording Serial Numbers • Add Serial Item • Allows entry of new serial number records • used for Inventory Adjustment, Count Adjustment, Cycle Counts

17. Recording Serial Numbers • Recording Serial Numbers from MRO Item • Add new, remove and view existing serial numbers • Scroll through list • Move serial number location within storeroom

18. Recording Serial Numbers Item Serialization Worksheet

19. Recording Serial Numbers Recording Serial Numbers from Work Order • Requirements view Launches item serialization worksheet Location of serialized item will be WO Entity to work on

20. Recording Serial Numbers • Record Serial Numbers from Work Order • Assets tab displays asset(s) created during the serialization of item(s) for this work order

21. Recording Serial Numbers Recording Serial Numbers from Inventory Transactions • Receipt • new serial numbers • Inventory Adjustment • Count Adjustment • Return to storeroom • existing serial numbers put back into inventory

22. Recording Serial Numbers • Recording Serial Numbers from Receipt Worksheet

23. Selecting Serialized Items • Allows user to select a serial number for a transaction • Used for: • Issue • Reclassification • Count Adjustment • Pick List Line • Cycle Counts.

24. Serialized Item Location • Location of serialized item will change with transaction • Issue – WO entity to work on • Reclassification – Storeroom • Count Adjustment and Cycle Count – no location change • Pick List Line – no change until issue transaction is posted

25. Selecting Serialized Items • Serial Number identified on Issue and Pick List • Use worksheet for more than one item

26. Removing Serialized Items from Inventory • Negative receipts (returns to vendor) • Cycle Counts • Business policy indicates whether associated asset will be suspended

27. Counting Serialized Inventory • Cycle counts for Serial Numbers • Opportunity counting not supported • Selection worksheet launched from Items, Count Item Details • Business policy indicates whether associated asset will be suspended

28. Updating Serial Items from Work Order Work Orders for Serialized items • Business Policy allows update of item’s cost • Book Value adjusted with work order costs at work order close • Allows update of serialized item's book value with: • Parts, and/or Labor • If more than one item serialized by work order, costs pro-rated across serialized items

29. Book Value • Book value informational only • Available for analysis and replace vs. repair decisions (e.g. determining when to scrap item) • When issued, item is still charged out at average unit cost

30. Moving Serialized Inventory Work Orders • Close dialog displays all serialized items located on WO entities • Serialized item can be moved

31. Serialized Inventory Locations • Move Serialized Item • Available at Work order close dialog • Serialized Item possible locations • Storeroom • Entity • Purchase Order • Work Order • Other

32. Swapping Serialized Inventory • Swap activity transaction generated when Serialized item that is also a trackable asset is: • Issued and charged to a work order • work order’s entity becomes new parent • Issued back into inventory • entity on the EAR identified on the Inventory Classification becomes new parent • Moved from one entity to another • entity on the EAR becomes new parent

33. Serialized Inventory • Movement tracked

34. Serialized ComponentsMatching entity record • Serialized components maintained in the storeroom can have a matching entity record for each individual component • Entity record is created automatically on receipt of a new serialized component • Entity record for serialized component resides under a ‘storeroom’ virtual parent entity until issued • Parent swap occurs automatically when a serialized component with matching entity is issued from storeroom Advanced

35. Repairable Spares Two major categories: • Non Tracked • items that are stocked, but no history of repairs or costs of repair are tracked on the individual item • Assumption is that part is repaired/restored to “like new” condition • Tracked • maintain their individual installation, repair and repair cost history • usually higher cost assets for which there is value in keeping the repair history

36. Charging Repair Costs Repair costs can be: • Expensed to the last location (where broken) • Expensed to inventory • Charged to another account

37. Serialized Components - Book Value • Options for assigning current book value • Most recent purchase price • Current average unit cost • Specific value • Book value can be adjusted by including repair costs originating from a work order against the serialized component entity Advanced

38. Setting Up Non Tracked Repairables • Value Lists • Replenishment Group V/L - add Repairable Spares • Replenishment Message V/L -add Review with Maintenance

39. Setting Up Non Tracked Repairables • Create the repairable MRO items with: • Maximum Quantity Replenishment Point • Replenishment message of Review with Maintenance • Replenishment Group of Repairable Spares • Replenishment Method of Suggest • Create a specific replenishment report named Repairable • Inclusion Criteria - Replenishment Group to Include - Repairable Spares only

40. Repairable spares - Creation of work request • Can be used in conjunction with serialized component function to track repair costs on repairable spares • Flag on item record signifies that item is repairable • Work request automatically created for the repair on the item when a repairable item is issued from the storeroom • Assumes that the issue of a repairable items indicates that an item has been removed from an entity and requires repair • Acts as “bookmark” Advanced

41. Repairable spares - Creation of work request • Work request can be identified and converted into a repair work order • Repair costs are applied against the entity where the repairable spare was installed • If spare cannot be repaired, WR can be cancelled and spare scrapped

42. Work Order Planning • Add requirements as normal for repairable and non-repairable parts • In the description of the work to be done: • identify that the removed repairable spare is to be repaired to like-new condition and returned to stores • If desired, a separate task can be created for the repair • If the spare is to be sent out, or a replacement purchased: • Create PO • Charge the PO to the work order

43. Stores issues for Repairables • Issue repairable parts • Create repair tag for the removed/returned part • identifies the item number, description of the defect and the repair work order number • Perform a negative return for the repaired spare, crediting the repair work order

44. Additional Setup for Tracked Spares Value Lists • Entity Status Value List: • In Service • Being Repaired (external, internal) • Available for Use • Scrapped • Etc. • Entity Typevalue list - Repairable spare

45. External Repair • If the spare is to be sent out, or a replacement purchased: • Create PO • Charge the PO to the appropriate work order

46. Setup Summary • Item Type V/L • Inventory Classification V/L • Work Request template for repair • “Generate Repair W/R” business policy • Reason for transaction V/L • Item record

47. Questions and Discussion