Shutdown, Outage and Project Cost Tracking Session ID#: This is a subtitle for the presentation Presented by: Name: Veeramani Ranganathan Title: Manager – ERP Systems & Operations Company: Intergen #JDEINFOCUS or add your own Twitter handle

Shutdown, Outage and Project Cost Tracking

Topics The Business Need Design Aims Process Summary Screens and Reports Usage Q and A

The Business Need Get Shutdowns clearly identified Get near immediate reporting of Actual and Committed Costs Avoid overspend when Major Contractors invoice late Using Shutdown history to improve future Shutdown planning Create and define Shutdowns and Shutdown Jobs quickly in JDE

Design Aims Support Planned Shutdowns, Outages, Projects, new Builds Make sure committed costs are visible and impact forecasts Keep the Engineering users in the world of Work Orders – not Accounts Provide a rolled up Cost report and Enquiry Easily create a new Shutdown from an old one or a model

Topics The Business Need Design Aims Process Summary Screens and Reports Usage Q and A

Process Summary Create Outage Work Order Hierarchy Check Structure is good Add / Revise Budget Estimates Buy Materials and Services Issue Stock Run Cost Reports

Work Order Hierarchy example Add One Top Outage Level Work Order Add Level 2 Work Orders and Budget Estimates Add Level 3 Detailed Work Orders Up to 10 levels can be used In practice 5 is enough

System Based Level 2 examples Gas Turbine GTA Steam Turbine STG Balance of Plant Switch Yard Sewage treatment Gas Turbine GTB Generator Heat Recovery Electrical Distribution Services (Crane, Safety, Scaffolding, Tools) Water Treatment Emergent Work Single Level 1 Work Order

Activity Based Level 2 examples Switchgear Maintenance PSSR Inspection Trevi Testing Crane Hire Scaffolding Insulation Cleaning Non Destructive Testing Boroscope Costs

3 level Hierarchy Example Top Level Work Order Purchasing Purchasing Gas Turbine Heat Recovery Switchyard Stock issue Stock issue Craft Hours Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order Craft Hours Stock issue Detailed Work Order Detailed Work Order Craft Hours Detailed Work Order Craft Hours

Shutdown Coding Every job in a Shutdown has the same Shutdown code Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A

Check Structure is good Only one top level job Every Work order has A parent in the hierarchy The same Shutdown code Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A Shutdown Code A

Rolled Up Costing Top Level Work Order Purchasing Purchasing Gas Turbine Heat Recovery Switchyard Stock issue Stock issue Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order Stock issue Detailed Work Order Detailed Work Order Detailed Work Order

Rolled Up Costing 1 $ 0 Purchasing Purchasing $100 $ 0 $500 Stock issue Stock issue $50 $80 $0 $0 $0 $200 Stock issue $0 $0 $0

Rolled Up Costing 2 $ 0 Purchasing Purchasing $100 + $50 $ 0 + $80 $500 + $200 Stock issue Stock issue $50 $80 $0 $0 $0 $200 Stock issue $0 $0 $0

Rolled Up Costing 3 $930 =$ 0 + $150 + $80 + $700 Purchasing $150 = $100 + $50 $80 = $0 + $80 $700 = $500 + $200 Stock issue Stock issue $50 $80 $0 $0 $0 $200 Stock issue $0 $0 $0

Topics The Business Need Design Aims Process Summary Screens and Reports Usage Q and A

Outage Set Up menu Fast paths OM for Outage Management OS for Outage Set Up OR for Outage Reporting

First choose a Shutdown Code Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders D17 = Fourth in 2017 A = First B = Second C = Third D = Fourth 16 = 2016 17 = 2017 18 = 2018 19 = 2019

Then add a Top Level Work Order Enter a new Shutdown Code. All Work orders in this outage must use this new code. Click here to create the Work Order This is the Top Level Work Order number Children will get this account number automatically as a default You can add attachments as usual This is the single top level job so it doesn’t need a parent. The top level job needs a new unused Shutdown Code Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders 2 3 1 4

Add Level 2 Buying Work Orders The top level job is the parent for all Level 2 Work Orders. Values from the Parent automatically populate this work order. Level 2 Work Orders Must have a postable Account Number Click here to create the Work Order This is the Level 2 Work Order number Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders 4 3 1 2

Add Budget Estimates 2 3 4 1 Select a Level 2 Work Order Enter an estimate or a revised estimate Click Apply We can lock the original Business plan Budget if needed Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders 2 3 4 1

Add Level 3 Detailed Work Orders Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders Enter the Level 2 Order here. Fields on the form will be filled in automatically. To add detailed instructions tick on here. Level 3 and below jobs should have an Equipment Identity Click Create here. An attachment prompt will appear. Outage Jobs can also be added using spreadsheets load applications. 2 4 1 3

Add Estimated Hours 1 2 3 1 Select one or more rows Click Row Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders Select one or more rows Click Row Click Estimated Hours 2 3 1

Add Estimated Hours 2 5 1 2 3 4 6 Enter one or more Craft Codes Enter the estimated date worked or leave blank Enter the Estimated man Hours Enter the Estimated number of people Click OK You can enter Contractor hours on this form Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders 5 1 2 3 4 6

Check Structure is Good Choose Outage Audit Report Enter your Branch and Shutdown Code Tick on to include opportunity jobs Click Submit 2 1 3 4

Outage Audit Results The Orphan count should be 1 – just the single top level 1 job. Every job should have a Planned Start Date so this should be 100% Bad parents should be zero. A parent is bad if it has a different shutdown code to the child. ‘Bad’ Objects are non Outage Accounts – can be legitimately used for opportunity jobs. Level 3 and below jobs should have an Equipment Identity so a high % is good here. 1 2 3 4 5

Costs on Work Orders Top Level Work Order Purchasing Purchasing Gas Turbine Heat Recovery Switchyard Stock issue Detailed Work Order Detailed Work Order Stock issue Detailed Work Order Detailed Work Order Detailed Work Order Stock issue Detailed Work Order Detailed Work Order Detailed Work Order Detailed Work Order

Costs on Work Orders 1 Items Cost Type Method Direct Purchase Materials Contractor Services Contractor Labour Committed when Ordered but not Received Actual When Received Custom PO Workbench or Standard P4310 using Work Order Subledger type W Purchasing Materials from Warehouse Committed on WO Parts List but not Issued Actual when Issued Standard WO Parts List Standard Issue Inventory to a Work Order Stock issue

Costs on Work Orders 2 Items Cost Type Method Direct Purchase Materials Contractor Services Contractor Labour Committed when Ordered but not Received Actual When Received Custom PO Workbench or Standard P4310 using Work Order Subledger type W Purchasing Materials from Warehouse Committed on WO Parts List but not Issued Actual when Issued Standard WO Parts List Standard Issue Inventory to a Work Order Stock issue

Custom Purchase Order Work Bench 1 Choose Work with Outages Find and select the Outage Work Order Click Row Click Create Requisition or Order as needed 1 3 4 2

Custom Purchase Order Work Bench 2 Enter the supplier The Account defaults to the Work Order Account Enter the details. The Account Number, Shutdown Code, Subledger and Subledger Type all auto populate Click Create Requisition 1 2 4 3 3

Report Costs 1 1 3 2 4 Choose the report you need Choose the output format. Enter the Branch and Shutdown Code Click Submit Add One Top Level Work Order Add Buying Work Orders and estimates Add Level 3 Detailed Work Orders Report on outage costs and estimates 1 3 2 4

Report Costs 2 Level 1 : Shutdown totals Level 2 : System totals Level 3 : Work order costs 3 Level 3 Purchasing is allowed 16416.00

Online Enquiry

New Shutdowns From Old 1

New Shutdowns From Old 2 Old Work Order New Work Order

New Shutdowns From Old 3

New Shutdowns From Old 4 1 2 3 Parent Child Structure is preserved Original Budgets are copied across Parts Lists are copied too

Topics The Business Need Design Aims Process Summary Screens and Reports Usage Q and A

Some Statistics on OCT usage From 2011, 214 Major overhauls/shutdowns/projects 45248 work orders generated This include Office relocations in two regions

Topics The Business Need Design Aims Process Summary Screens and Reports Usage Q and A

Q&A

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