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Maintenance Management

Maintenance Management. The Replacement of Legacy MMS Software With Oracle EAM. AGY Background Information. AGY was formed as a joint venture between Owens Corning and Porcher Industries in late 1998. New company with NO enterprise software Owens Corning systems were NOT Y2K compliant

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Maintenance Management

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  1. Maintenance Management The Replacement of Legacy MMS Software With Oracle EAM

  2. AGY Background Information • AGY was formed as a joint venture between Owens Corning and Porcher Industries in late 1998. • New company with NO enterprise software • Owens Corning systems were NOT Y2K compliant • Produces Glass Fiber Yarns, very capital intensive. • Melt earthen materials to create glass • Spin glass onto bobbins for sale • Two manufacturing facilities: Aiken, SC and Huntingdon, PA. • Headquartered in Aiken • Sales office in Lyon, France

  3. AGY Maintenance By The Numbers • 90 Craft personnel in Aiken and 69 in Huntingdon • 125 Work Orders generated per day • 18,000 items in stores inventory • 4 Planners / schedulers • 5,100 Named Assets

  4. Production Orders • Production Results • Material Usage • Inventory Level • Financial • Breakdowns • Repairs • Preventative • Cleaning • Machine Specs • Run data • Data collectors • Paging • Text Messaging AGY MMS Integration Strategy Oracle 11i MMS MES Controls

  5. AGY Technology Timeline • 1999 - Oracle Applications v11.0 (AP/AR/GL) • 1999 - Oracle GEMMS v4 (OF/PM/INV) • 1999 - Datastream MP2 v6 (MM, Purchasing) • 2001 - Camstar Insite v3 (Manufacturing Execution System) • 2003 – Rockwell Controls (PLC) • 2004 - Oracle Apps Fresh Install v11.5.8 • Added Oracle Process Manufacturing, Purchasing • Emerged from Chapter 11 Bankruptcy • 2005 - Oracle EAM v11.5.10.2 • Added iProcurement

  6. Case for Replacement of Legacy MMS • MP2 was no longer strategic product for Datastream • Maintenance wanted increasing functionality out of the MMS • Barcoding of spindle breakdowns • Interface with Predictive Maintenance software • Repairable spares • MP2 running on de-supported version of Oracle Database • Poorly supported integration between MP2 and Oracle Purchasing/Inventory/General Ledger • Planned upgrades to Oracle Applications put interfaces at risk

  7. Legacy MMS Replacement Strategy • Assemble team to focus on Maintenance Fitness For Use. • Included both plants, Engineering and IT. • Issue Request for Proposal (RFP) based on Fitness For Use of Maintenance and IT. • Conduct customer reference meetings. • Use product demonstrations to prove capability based on RFP response. • Present recommendations to Senior Leadership Team. Decision came down to Datastream 7i or Oracle EAM

  8. Legacy MMS Replacement Decision • Datastream 7i and Oracle EAM roughly equivalent • Both are new implementations (7i is NOT an upgrade) • Roughly the same implementation costs • Functionality the same • Strategic fit better with EAM • More functionality to be delivered out of Oracle Applications requires excellent integration (Production Management, Fixed Assets) • Internal support of 7i interface likely to be high, prefer one vendor.

  9. EAM – AGY EnhancementsNO CHANGE TO ORACLE APPLICATIONS • Emergency Work Order form • No EAM knowledge required • Can see other Work Orders that may already be entered • Uses Oracle’s Work order interface • Oracle Alert to send emergency pages to Craft personnel • Sends email through internet to paging service • Text on pager shows location to be served • Interface to AGY Specification Management System • Creates Work Order when a product change is scheduled • Uses Oracle’s Work Order interface • Personalization of Self Service • Added Pick Ticket button to run report from materials tab

  10. EAM – Emergency Work Order Form

  11. EAM Personalization – Pick Ticket Personalized Button

  12. EAM Critical Success Factors • Support from Senior Leadership • Approved strategic decision, funded project • Provided resources, communicated urgency • Proven implementation partner • Experience in Maintenance best practices • Dedicated implementation team • Thorough testing • Initial pilot to train the team • Additional dry runs as needed • Validation of data migrations • Proper training • Craft and Planners • iProcurement for all Salaried personnel

  13. EAM Lessons Learned • Be very aggressive with Oracle Support on priority issues • Several priority one TAR’s put project at risk • Test data migration early and often • Tried to change Asset naming several times, extended timeline • Define custom reports early and have ready for testing • Delivered key reports after go-live

  14. EAM - Benefits • Individual craft work backlog/schedule available on any PC in the plant • Personalized by log on criteria • Both labor and material costs roll up to the asset • Activities can be associated to individual assets or asset groups • Quality plans can be generated to require specific information related to repairs • Self service allows broad operational functionality to the floor • Forms allows “behind the scenes” functionality that remains transparent to floor users • Aside from native Oracle integration with purchasing, inventory, WIP, AR/AP, GL, and other modules, it can be easily integrated with other systems ( PES, MES, etc ) • Third party reporting ( BO ) friendly

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