01-Sep-2021 Functional Requirement Document CBL - D365 & Porini Implementation Module Area: Enterprise Asset Management ICT CRESCENT BAHUMAN LIMITED
Functional Requirement Document Version – 1.0 Enterprise Asset Management Contents 1 Preface .................................................................................................................................................. 5 2 Version Control ..................................................................................................................................... 5 3 Overview ............................................................................................................................................... 9 4 Organizational Responsibility Structure / Hierarchy........................................................................... 10 4.1 Organization Structure................................................................................................................ 10 4.1.1 Engineering Organization structure View ........................................................................... 10 4.1.2 Textile Maintenance Organization Structure View............................................................. 12 4.1.3 Sewing Maintenance Organization Structure View ............................................................ 13 4.2 Roles and Responsibilities Hierarchy .......................................................................................... 13 4.2.1 Divisional Head.................................................................................................................... 13 4.2.2 Department Head ............................................................................................................... 14 4.2.3 Asset Administrator ............................................................................................................ 14 4.2.4 Planner ................................................................................................................................ 14 4.2.5 Supervisors.......................................................................................................................... 14 4.2.6 Workshop Owners .............................................................................................................. 14 5 Assets .................................................................................................................................................. 15 5.1 Locations ..................................................................................................................................... 15 5.2 Assets / Sub-Assets ..................................................................................................................... 15 5.3 Asset Commissioning/Decommissioning Process....................................................................... 17 5.4 Meters......................................................................................................................................... 17 6 Job Plan Setup..................................................................................................................................... 18 6.1 Create Work Template-Job Plan] ................................................................................................ 19 6.2 Specify Activities to Perform....................................................................................................... 19 6.3 Specify Crafts & Skills Required .................................................................................................. 19 6.4 Specify Tools ............................................................................................................................... 20 6.5 Specify Services........................................................................................................................... 20 6.6 Specify Material .......................................................................................................................... 20 7 Schedule Definition – Preventive Maintenance ................................................................................. 21 Page 2 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 7.1 Create PM Schedule.................................................................................................................... 21 7.2 Meter Based PM ......................................................................................................................... 22 7.3 Time Based PM ........................................................................................................................... 23 7.4 Standard Job Plans & PM-Activation and Modification Process................................................. 23 8 Condition Based Maintenance............................................................................................................ 23 8.1 Create Condition Monitoring Points ........................................................................................... 24 8.2 Job Plan/PM Attach..................................................................................................................... 26 9 Routes Setup ....................................................................................................................................... 26 9.1 Create Route ............................................................................................................................... 26 9.2 Specify Assets/ Locations............................................................................................................ 27 10 Corrective Maintenance ................................................................................................................. 29 10.1 Problem Reporting...................................................................................................................... 30 10.2 Create Work Order...................................................................................................................... 30 10.3 Work Order Generation Process................................................................................................. 31 11 Standard Job Plans & PM – Activation and Modification Process .................................................. 31 11.1 Route to WORKFLOW ................................................................................................................. 32 11.2 Approval...................................................................................................................................... 33 12 Safety Plans Setup and Attachment................................................................................................ 34 12.1 Safety Plan Request .................................................................................................................... 34 12.2 Define Safety Plan ....................................................................................................................... 34 12.3 Hazard Selection ......................................................................................................................... 35 12.4 Define Hazard.............................................................................................................................. 36 12.5 Define Tag out/ Lock out............................................................................................................. 37 12.6 Define Precautions...................................................................................................................... 37 13 Failure Codes and Classes Setup..................................................................................................... 38 13.1 Create New Failure Class............................................................................................................. 38 13.2 Specify Problem, Cause and Remedy.......................................................................................... 38 13.3 Failure Reporting Process ........................................................................................................... 39 13.3.1 STEP # 01 – [Select Record]................................................................................................. 40 13.3.2 STEP # 02 – [Failure Reporting]........................................................................................... 40 14 Work Order Generation .................................................................................................................. 41 14.1 Create Work Order...................................................................................................................... 41 Page 3 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 14.2 Schedule Work Order.................................................................................................................. 42 15 Service Requests ............................................................................................................................. 44 16 Items Issuance................................................................................................................................. 45 17 Requirements.................................................................................................................................. 45 18 Reports :.......................................................................................................................................... 48 Page 4 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 1 PREFACE This document intends to capture business process requirements of Crescent Bahuman Limited & Crescent Textile Mills Limited for implementation of Microsoft Dynamics 365 Asset Management System. The current scope of the project covers only Plant Machinery Maintenance Management. The target audience of the document includes staff of Engineering & Maintenance departments, Supply Chain department. Currently CBL is using IBM Maximo Assets Management Solutions for machinery maintenance processes. 2 VERSION CONTROL The Version Control Table would be updated each time a change is made to the document. It would be maintaining a record for the following information: ✓ Version number ✓ When the change was made ✓ Who made it? ✓ What was the major improvement done? Version # Date Published Author Update information V0.1 23-August-2021 V0.2 Arsalan Mehboob Initial draft document V0.3 01-Sep-2021 Arsalan Mehboob Final Version 02-Sep-2021 Arsalan Mehboob Final Version Page 5 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management FRD Acceptance Sign Off CBL FRD Sign Off – HODs Mr. / Ms. ___________________________________________ Department ___________________________________________ Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Mr. / Ms. ___________________________________________ Department ___________________________________________ Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Mr. / Ms. ___________________________________________ Department ___________________________________________ Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Page 6 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management Mr. / Ms. ___________________________________________ Department ___________________________________________ Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Mr. / Ms. ___________________________________________ Department ___________________________________________ Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Mr. / Ms. ___________________________________________ Department ___________________________________________ Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Page 7 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management CBL – Project Manager’s Sign Off Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Date Name Signature CBL – Project Manager’s Sign Off Acceptance: Accept Deliverable Reject Deliverable with Reason Reason for rejection (if rejected) Date Name Signature Acceptance: CBL – Project Head Reason for rejection Accept Deliverable (if rejected) Reject Deliverable with Reason Page 8 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management Date Name Signature 3 OVERVIEW Enterprise Asset Management (EAM) solution is capable of complex fixed-plant support, with particular importance attached to hierarchical plant structures, condition and performance monitoring, preventive maintenance, and shutdown planning for refurbishments. Below are the major areas/sub modules of Maximo currently being used by CBL for plant maintenance. We will be elaborating each section’s AS-IS process along with requirements in coming sections. • Assets/Sub-Assembly Setup • Assets Spare Parts Setup • Asset Commissioning • Decommissioning • Meters Setup • Job Plan Setup • Schedule Definition • Preventive Maintenance • Condition Based Maintenance • Corrective Maintenance • Failure Codes & Classes Setup • Failure Reporting • Work Order Generation • Work Order Approval • Work Order Actuals Data Entry • Work Order Completion and Closure • Workshops setup Page 9 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management • Service Requests setup 4 ORGANIZATIONAL RESPONSIBILITY STRUCTURE / HIERARCHY 4.1 ORGANIZATION STRUCTURE Organizational structure is primarily a hierarchical concept of subordination of entities that collaborate and contribute to achieve one common goal. CBL have different organizational work responsibility structures followed for Electrical and Mechanical work. Mainly there are 3 main areas/divisions in context of work responsibility structure. • Engineering • Textile • Sewing Below is the hierarchical view of these areas 4.1.1 ENGINEERING ORGANIZATION STRUCTURE VIEW Page 10 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management Page 11 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 4.1.2 TEXTILE MAINTENANCE ORGANIZATION STRUCTURE VIEW QA Grading Fabric Lab FTL Yarn Lab Page 12 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 4.1.3 SEWING MAINTENANCE ORGANIZATION STRUCTURE VIEW 4.2 ROLES AND RESPONSIBILITIES HIERARCHY Currently below are the main roles/responsibilities configured in Maximo to map with above organization structure. • Divisional Head • Department Head • Asset Administrator • Planner • Supervisor 4.2.1 DIVISIONAL HEAD Currently divisional head role is configured at top level for each organization structure i.e. Engineering, Textile and Sewing. This is the main role for Final Approval of purchase requisitions. Page 13 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 4.2.2 DEPARTMENT HEAD Department head is reporting to relevant divisional head and first level approval for purchase requisitions. All job plans and preventive maintenance plans are approved by department heads. 4.2.3 ASSET ADMINISTRATOR Asset administrators are owner of all assets/sub-assets related to their relevant locations. All assets related activities like asset commissioning, decommissioning, movements etc. are the core responsibilities of Asset administrators. 4.2.4 PLANNER Planner is the main maintenance planning role. Planners are custodians for All Job plans, routes and preventive maintenance plans for their relevant locations. All planned materials and labor addition on job plans are also responsibilities of planners. 4.2.5 SUPERVISORS This role is responsible for all corrective, condition based and service work orders creation and closure along with actual labor and actual material. Meter readings entry of their respective areas is also the responsibility of supervisors. 4.2.6 WORKSHOP OWNERS These are the owners of their relevant workshops/labs. All service request generated are auto assigned to respective workshop owners. Work orders creation and closure against service requests is the main responsibility of workshop owners. Page 14 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 5 ASSETS 5.1 LOCATIONS Locations are created as per organizational structures described above. GL codes are mapped against each location having profit & cost centers segments to charge the maintenance cost of assets commissioned at that location. Currently locations have parent/child relation to build. 5.2 ASSETS / SUB-ASSETS An asset can be setup at operating location based on following mechanisms: • Asset creation without inventory & purchasing transaction • Asset purchase and issuance to operating location • Asset assembling & movement to operating location/installation Asset number are generated automatically. This auto-generated asset number are communicated to Finance Department for “Fixed Assets Record”. Page 15 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management An asset can also be a child of another asset and this relation can be maintained in Maximo by providing asset # in parent field on assets screens. An asset’s spare parts are identified by maintenance department on floor. This data is communicated to Inventory department so that they can create Asset Spare Parts. These parts are later on attached to asset for tracking. Page 16 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 5.3 ASSET COMMISSIONING/DECOMMISSIONING PROCESS Asset commissioning process is triggered by Asset Administrator for setting asset’s status to operating after its movement to production location. While asset is also decommissioned by asset administrator on need basis by changing its status to non-operating. 5.4 METERS Currently meters of type continuous having unit of measure Hours is configured. This meter is attached to mainly PG assets like engines, LFO and HFO etc. as shown in below screenshot. Page 17 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 6 JOB PLAN SETUP Job Plan setup is the responsibility of the Planner, as it is required to create the Preventive Maintenance Schedule. Below are the major components of Job Plans. a. Activities/Tasks b. Planned material c. Planned labor/crafts d. Services All the above four components are auto copied on preventive maintenance work orders planned sections from job plan and actuals are populated by supervisors accordingly. Only active job plans become available to attach with preventive maintenance plans. Job plans status is also being maintained and workflow is configured on Job plans for their activation and deactivation as below. • Job plans are created by Planner. • Submitted for Approval to department heads. • When department approve, its status is updated to active and vice versa. Process Flow Diagram Page 18 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 6.1 CREATE WORK TEMPLATE-JOB PLAN] New Job Plan are created having default status “DRAFT” by filling the mandatory fields and those which required. 6.2 SPECIFY ACTIVITIES TO PERFORM Each Job Plan consists of multiple tasks, which are specified in detail. 6.3 SPECIFY CRAFTS & SKILLS REQUIRED In labor, user can mention the labor or can also define only the craft and skill required to perform a certain activity. User can attach the labor with individual activity. Page 19 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 6.4 SPECIFY TOOLS If any tools are required, specify those as well. 6.5 SPECIFY SERVICES If any Service is required for the Job Plan, it would also be mentioned in the respective tab. Service can also be attached with tasks individually. 6.6 SPECIFY MATERIAL Material and its quantity required to fulfill the Job Plan will also be mentioned with individual item. Moreover, user can also mention the Store for material reservation as well. Page 20 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 7 SCHEDULE DEFINITION – PREVENTIVE MAINTENANCE Preventive Maintenance planning are generated by Planner on the basis of which work order will be created and executed. Process Diagram 7.1 CREATE PM SCHEDULE New Preventive Maintenance are created having auto generated PM number. Planner enters the required data and select the Job Plan, if required. PM can be for an Asset/Location/Route. Lead time Active: If checked, means the Work Order will be generated before the scheduled date with the delta of entered Lead Time. Page 21 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management PM can be Time Based or Meter Based. 7.2 METER BASED PM To identify when the work order will be generated, frequency is defined which can be on the basis of meter. In this case, meter will be attached to identify the condition. Page 22 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 7.3 TIME BASED PM Frequency can also be set on the basis of time which can be in Days/Weeks/Months/Years. 7.4 STANDARD JOB PLANS & PM-ACTIVATION AND MODIFICATION PROCESS For the approval of PM and its activation, “Standard Job Plans & PM-Activation and Modification Process” is triggered. if meter regarding which PM needs to be triggered does not exist, then Planner request the System Administrator to define Meter accordingly. System Administrator execute the “Meter Setup” process to define the Meter. 8 CONDITION BASED MAINTENANCE For maintenance to be triggered, there are some conditions marked as Condition Monitoring Points needs to be satisfied. Page 23 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 8.1 CREATE CONDITION MONITORING POINTS Create Condition monitoring points which are associated with a Meter. There are three types of meters - Gauge, Characteristic and Continuous, Condition monitoring points are defined on the basis of Gauge or Characteristic Meters. Continuous meters are evaluated by association with an Asset/Location. CASE: Gauge Meter In case of Gauge meter, user identify the upper and lower limit of condition violation and action that will be taken. Measurements are entered on Inspection in the respective fields. All the measurements are shown in the history area with the entered dates. Page 24 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management CASE: Characteristic Meter In case of Characteristic meter, user identify the characteristic from the defined meters on which a certain PM needs to be executed. Measurements are entered on Inspection in the respective fields. All the measurements are shown in the history area with the entered dates. Page 25 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 8.2 JOB PLAN/PM ATTACH Attach the CM with Job plan / Preventive Maintenance, if exists, and if not then Planner will define JP/ PM by executing “Job Plan Setup” OR “Schedule Definition – Preventive Maintenance” process respectively. CASE: Meter Setup Required (Meter Based PM) In STEP # 1, if meter with which CM needs to be triggered does not exist, then Planner request the System Administrator to define Meter accordingly. System Administrator execute the “Meter Setup” process to define the Meter. 9 ROUTES SETUP Planners create asset’s inspection routes record in the system. Inspection plan can be for an individual or multiple assets and its sub-assemblies. 9.1 CREATE ROUTE For Inspection Plan, Planner first create Route in the application. Planner can group multiple Assets and Locations against which a single Inspection Plan is required. Page 26 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management Screenshots 9.2 SPECIFY ASSETS/ LOCATIONS Specify the Assets/ Locations in the Route. There are three types of Routes on the basis of which activities handling become different. CASE: Create Child Work Orders In this case, work orders for each Asset/Location are created. It is used when there are multiple activities to be performed on each asset/location. These activities are triggered from Job plan which is attached with each asset/location. In this case, PM attached have no Job Plan associated with it. Page 27 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management CASE: Entries in the Work Order’s Multi Asset, Location and CI Table In this case, Route is defined to group Assets/Locations for inspection in a single go. There is no individual task list for each asset/location. In this case, a common Job Plan is attached with the PM which uses this Route describing activities for all the assets/locations. Page 28 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management CASE: Create Work Order Tasks In this case, description explain the task which needs to be applied on different Assets/Locations. The sequence is applied by using “Sequence” field and all the activities required on same Asset/Location or on different are mentioned while defining the route. 10 CORRECTIVE MAINTENANCE For any breakdown or fault in machinery, corrective maintenance required which is executed by supervisor on reporting from the requestor. Page 29 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 10.1 PROBLEM REPORTING This is a manual process. From the production floor, person who is facing the problem in an asset report the issue to concerned maintenance supervisor. The complaint is registered via email or verbally. 10.2 CREATE WORK ORDER On receiving the complaint, Supervisor create a work order of type “Corrective Maintenance”. Supervisor manually notify the requestor about work order initiation/completion and also email the Planner about work to be performed. Page 30 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 10.3 WORK ORDER GENERATION PROCESS After creating Work Order of type “Corrective Maintenance”, supervisor execute “Work Order Generation Process”. 11 STANDARD JOB PLANS & PM – ACTIVATION AND MODIFICATION PROCESS Planner initiate this process for Job Plan & PM activation and modification. Process Diagram Page 31 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 11.1 ROUTE TO WORKFLOW Planner select the record needs to be activated or updated and float it to the Department Head. “Preventive Maintenance” For the Planner, job plan and preventive maintenance having status “DRAFT” will be editable and needs to be activated by Department Head for which needs to routed by Planner. The job plan Page 32 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management and preventive maintenance having status “ACTIVE” or “INACTIVE” will be read only for Planner and to update them, require approval from Department Head. 11.2 APPROVAL The JP/ PM routed to department Head will be shown in Maximo-Inbox. Department can have three options: CASE: Allow Planner to Change In this case, Job Plans need to be de-associated from PMs and its status is changed to “DRAFT” so that Planner can modify it and route it to Department Head for approval. CASE: Work on a new Version Department Head can have an older version and give a go ahead to change the JP/PM by making a copy of it and keeping its status “DRAFT”. CASE: Activation If Department Head considers the JP/PM acceptable then change the status to “ACTIVE” making it available for use. Page 33 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 12 SAFETY PLANS SETUP AND ATTACHMENT Safety Plans are generally common for an organization. Maximo gives the option to create the safety plans and attach them with Job Plans or Work Orders. 12.1 SAFETY PLAN REQUEST If the Safety plan already exists and it fulfills the needs, Planner attach it with the Job Plan/Work Order. Otherwise, Planner request the System Administrator to create the Safety Plan according to the specifications. This is a manual process. 12.2 DEFINE SAFETY PLAN System Administrator create a new Safety Plan. Asset/Location is mentioned for which Safety plan is required. Page 34 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 12.3 HAZARD SELECTION Select the hazard which exists. Hazard’s remedy is in the form of Precautions or Tag out. CASE: Hazards with Precautions If there are any hazards whose precautions need to be taken, that is selected and attached with the Safety Plan. If any hazardous material is involved then it is mentioned in the respective tab. Page 35 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management CASE: Hazards with Tag Out/ Lock Out If there are any hazards whose Tag outs and Log Outs required is selected and attached with the Safety Plan. 12.4 DEFINE HAZARD Define the hazard and mark as either Precautions or Tag outs and fill the respective data accordingly. “Precautions” Page 36 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management “Tag Outs” 12.5 DEFINE TAG OUT/ LOCK OUT Define the Lock Out/Tag Out and associate the Asset/Location, if required. 12.6 DEFINE PRECAUTIONS If Precautions are not defined, they need to be defined first. Page 37 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 13 FAILURE CODES AND CLASSES SETUP This process is initiated by the System Administrator on Supervisor request to create new failure codes and classes in the system. 13.1 CREATE NEW FAILURE CLASS System Administrator create new failure codes and classes in system on manual request from Supervisor. 13.2 SPECIFY PROBLEM, CAUSE AND REMEDY System Administrator either select existing failure codes for Problem, Causes and Remedy or create new codes. Page 38 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 13.3 FAILURE REPORTING PROCESS Data Entry Operator use this process to provide failure information for “In Progress” Work Orders. Page 39 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 13.3.1 STEP # 01 – [SELECT RECORD] Data Entry Operator search “In Progress Work Orders” 13.3.2 STEP # 02 – [FAILURE REPORTING] Select “Failure Class”, specify Problem, Cause, Remedy, Remkars & Date for that Failure Class. Page 40 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 14 WORK ORDER GENERATION This process will be initiated by Supervisor/Planner for creating, scheduling and executing work orders. Work Order number will be auto generated. 14.1 CREATE WORK ORDER Supervisor/Planner create a work order for an Asset/Location and specify job plan or enter tasks to be performed. Page 41 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management As each location is mapped with a cost center, so up to cost center segment, GL segments are fetched from operating location and Natural Account from the commodity group associated with the planned inventory item or service to trigger the debit and credit transactions. 14.2 SCHEDULE WORK ORDER After creating a manual work order or the work order generated by Preventive Maintenance or Condition Monitoring Cron Task, next step is to schedule the work order in which Scheduling Information is provided and planned Material, Labor, Tools and Services (if required) are specified. Page 42 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management • Work Order Approval - In this step Work Order with status “WAPR” is routed for approval. • Actual Data Entry - In this step, Actuals Data Entry is performed on Work Order with status “INPRG” • Failure Reporting - After Actuals Entry before work order completion, data entry operator enter failure information. • Work Order Completion & Closure - In this step, Work Order having status “INPRG” is completed by supervisor. Planner is informed for closure who either close work order or assign them to Department Head for closure. Page 43 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 15 SERVICE REQUESTS Service requests are being used by almost all departments. Service requests can be created against any asset or location. Currently multiple workshops/labs are configured in Maximo as below Each of above workshops have owner mapped against it in system and service request is auto assigned to that owner on creation and its default status is QUEUED. Then owner changes its status to in progress and creates work order against that service request and issue material against that work order. Page 44 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 16 ITEMS ISSUANCE Currently all spare parts inventory is in D-365 and issuance demand is also generated in D365. There Work order journal type is selected by user than user selects the allowed cost center and system auto populates the Approved work orders list from Maximo against selected cost center. 17 REQUIREMENTS 1. Spare Parts List and attachment with Assets 2. Stock reservation at department level with View rights to all users 3. Stock report based on demanded person & Reports requirements (Formats). 4. Outsource service/In-house service outsourced cost mechanism to Assets Supplier wise. Page 45 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 5. Preventive maintenance Plan for fixed days cases (Monthly maintenance update / Adjustment option) 6. PM should consider Calendar/Off days leaves and FOC stock segregation 7. Standard Cost + Batch wise Cost is required for High value Spare parts 8. Stock is piling up & expiring due to Overstated cost & reason is Moving AVG costing method 9. High value spare parts consumption costs are required to distribute on useful life? 10. Budget working reports are required based on previous year consumptions 11. IRNs are not properly entered on time in System e.g Rice HusK, Fuel etc 12. Portal report should be Live for Fuel/Furnace 13. Planned Labor should auto populate on Actuals and user should have rights to modify 14. To Capture Parts inspection and conditions parameters in System 15. Maintenance Checkpoints in Job Plans and Master Plan for electrical and mechanical 16. Meter bases readings should be Acquired automatically 17. Electrical & Mechanical PM plans should be synchronized in system ( 18. Sizing and Rebeaming should have separate cost centers 19. Downtime other than maintenance should be captured with reason 20. Downtime Summary report should not show machines down less than 24 hours, but its' detail report should be available 21. Cotton issuance is currently charging to Blow Room 22. SR closure intimation and report required for especially material issuance cost. 23. Both electrical and mechanical work orders should be synchronize by date and time. 24. Preventive maintenance plan is required machine based and route based for SM. 25. Currently machine type based excel PM plan is being followed. 26. Asset #, FAR# and serial # are required in new system 27. Machine type was Jobs plans are required 28. Wimetrix machine identity is also required to map in new system 29. Asset wise (Asset#, Serial #, FAR#) based consumption report is required 30. Asset’s data needs to revisit as currently Maximo assets data for Sewing is not up to date? Page 46 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 31. Sewing parts stock location is required in system.? 32. Sewing maintenance (05) item classes' item codes are required as per legacy ERP item code 33. Replace required items need to revisit with the consent of Store and Finance. The Consumable items replacement should be not required. 34. Labor data should be auto synched from HR. 35. While Marking Asset as Commission/decommission workflow is required. 36. When New Asset Received, intimation like email sent to PR creator. 37. While issuance against Work Order, non-maintainable item can also be entered. 38. Tab/Mobile is required to supervisor on field for record updating. I-e check safety measures or Work Order closure. (Need to cross check project scope and hardware cost). 39. Material can also be added in Work Order even after Approval (before Work Order Closure). 40. Asset wise Budget Allocation report required. 41. In Preventive Maintenance days like GH, OFF can be easily handled. 42. Statuses should be lean in Work-Order status. 43. DEO/Supervisor can open failure code but must be approved by planner. 44. PR should not be cancelled/Rejected by buyer without Approval of PR creator. 45. Item Price also be visible on IRN form. 46. In PR form Available balance field is required. 47. In Demand Note form Item Price field is required. 48. Purchase agreement and PO rate report is required. 49. Indenter wise available stock 50. Work Order closing and approval takes too much time. 51. The user customized dashboard required for same functional area. 52. IGP notification with indenter name. 53. Service items financial dimension should not be recorded by user. 54. Utility consumption should be incorporate EAM instead off ERP legacy support. 55. FOC Outward GATE PASS FOR Non-RETURNABLE / Sample and Returnable items. 56. New items code should be process in system. Page 47 of 48
Functional Requirement Document Version – 1.0 Enterprise Asset Management 57. String length for item description should be longer as it was in previous systems. 58. Item code for a single item should be same for local, import and service PRs with option of selection between local/import/service condition codes. 59. SR initiator should have rights to re-open SR in case needed. 60. Work orders against SR with material should get approval from concerned HOD. 18 REPORTS : 1. Demand Status & department selection report. 2. Pending Demand report. 3. CC /Location Type Issuance (Department wise/WO wise & Assets) report. 4. PO Detail report. 5. IRN edit list with price report. 6. Indenter wise available stock. 7. Work order detail report. 8. SR detail report. 9. Maintenance schedule report (calendar type with asset name and PM name). Page 48 of 48
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