5TH Annual TANKS AND TERMINALS CONFERENCE

BENEFITING FROM
DATA MANAGEMENT
Dubai - 15 - 17 September, 2014

PRESENTER : V. Murali - SHELL, Global Process Manager, Materials Operations

m.venkataraman@shell.com - +91 9962004899

CONTENTS & TAKE-AWAY FROM THIS SESSION

AREA OF FOCUS

CRITICAL ELEMENT

TAKE-AWAY

FIRST TIME RIGHT DATA MANAGEMENT

CONNECT WITH ALL ASSOCIATED

STAKEHOLDERS ON SOURCE DATA

DATA ACCURACY AND COMPLETNESS

MANAGING ASSET (TECHNICAL) DATA

PM MODULE, FUNCTIONAL
LOCATION, EQUIPMENT
HIERARCHY & DATA LIBRARY

RELIABLE MAINTENANCE PLAN WITH

GOOD CONTROL

MANAGING MATERIALS AND VENDOR

DATA

UNIQUE IDENTIFIER, CLEAR

SPECIFICATIONS, AVOID
DUPLICAATES, CORRECT VENDOR,
RIGHT PRICE AND LEADTIME

COST EFFECTIVE CONTRACTING AND

PROCUREMENT PROCEDURE AND
EFFECTIVE MATERIALS
MANAGEMENT

DATA PROCESS AND CONTROL

CREATE AND MAINTAIN ACCURATE

DATA. PERFORM DATA
STANDARDISATION AND DATA
QUALITY CONTROL

RESPONSIBILITY & ACCOUNTABILITY

COST OF POOR DATA PROCESS

NAVIGATE FROM SIMPLE

MAINTENANCE STEPS TO
COMPLICATED DATA CAPTURE
MODEL SPENDING OVER 10-TIMES

ADDITIONAL SPEND, MORE

RESOURCE DEPLOYMENT, FIREFIGHTING MODE OF DATA CAPTURE

BENEFIT OPPORTUNITY

SAVE ON RUSH ORDERS.

IMPROVED CRAFT EFFICIENCY.
AVOID ASSET DOWNTIME

MAINTENANCE OF EQUIPMENT AS
PER SCHEDULE. ENHANCE
PRODUCTIVITY

DATA MANAGEMENT FIRST TIME RIGHT

INVOLVE RIGHT
PARTIES
Source PM data
Plant maintenance data. Capture all
SAFETY CRITICAL AND
OPERATIONS CRITICAL equipment.
Ensure clear functional location.
Apply Equipment HIerachy

Source Spare
Parts
Ensure all maintenanable
equipment are supplied with spares
requirements. Clearly capture
interchaneability, recommended
spares and lead time

Project engineers, EPC or EPCM

contractors, Contracts &
Procurement, IM/IT team

Vendor Data
Gather as part of project handover
all vendor and their contacts. For
critical and licence operated
equipment ensure data handover.
For bought-out materials identify
original equipment manufacturer

OPTIMAL
DATA

Clear data interface

Asset
Documentation
Ensure manufacturer data
books, vendor data books are
properly handed over. Crosscheck Capital project asset
accquisition with that of
handed over documents

Data transition from project to run

and maintenance data system.
Ensure Contract TERMS &
Conditions are adequate cover

Managing ASSET (Technical) data

Total & Comprehensive database of
assets owned
Equipment classifications: Safety Critical
Operational Critical & Others
Assigning Bill of Material and Task list

Plant
maintenance data
Functional Location

Unique and related identifier

Plant, Unit and equipment nomenclature
Linked with (finance) Valuation Class

Equipment Hierarchy

Data Library

Parent Equipment
Child & Grand-child Equipment
Bulk requirements
Consumable requirements

Master data source

Mass storage, electronic database
Easy access and user friendly browsing

Managing Material & Vendor data

Materials
Material Interchangeability

Supporting Materials data

Vendor Data

Unique identifier
Standard catalogue management
Avoidance of Duplicates
Easy to browse for optimum usage

Clear link of material usage across various

equipment/locations
Ability to identify correct ORIGINAL
EQUIPMENT MANUFACTURER

CAPITAL spares and special tools

Mechanical & E&I bulk materials
Consumable materials
Clear specifications (without over or under
stating)

Identify and maintain Original Equipment

manufacturer and direct source
Have clear unique identification such as
model and serial number of equipment
Apply vendor recommended lead time

Managing data Process & Controls

Data Creation
Data Maintenance

Single (one-offs) requests

Bulk requests from projects
Validation of data source
Validation of data quality

Regular update of changing assets

Regular deletion of removed assets
Continuous Improvement Data(Data
Uplift)

MASS Data Support

Data Standardization

Data Quality Standards

Data Management Processes unified
IT Tools for Data Request Processing

Capital Projects Data

Master Data Modeling
Data load Implementation
Data Governance & Assurance

poor data PROCESS

Docs Rule of Ten

1-units

1 unit
Equipment
to be
maintained

Is the data
available &
correct?

Yes

Complete
work as
planed

Steps to fix errors:

No

9-unitss
Fix
errors

1.

Check documents for equipment data

2.

When data not available, physically check

the equipment for details

3.

Connect with vendor to get materials

required for maintenance

4.

Place RUSH ORDERs to meet schedule

5.

Postpone the work and re-work when

6.

Cancel the planed activity and risk asset

down-time and loss of production

Costs ten times higher for defective data as it involves rework. (Pay high price for rush-order, deploy resources,
systems, tools to fix, risk equip brake down & production loss
7

Benefit Opportunity when asset data is correct

Reduce Expediting
Costs
Craft Efficiency Procurement

We are actively using BoM work to

check lead time make improvements
Estimated $---k per asset/yr

We are seeing alot of new parts now

in BoMs which are not on contracts.
Buyers move from reactive to
proactive Est $---k per assett/yr

Cost of RUSH
ORDERS
Materials in the past as ADHOC
rmaintenance requirements thru
generics and rush orders
Estimated $---mil per asset/yr

Craft Efficiency Maint PlanTime

Can prepare inventory a lot
quicker than when we had to go to
manufacturer & get quote

Benefits

Optimisation
Inventory Levels &
Surplus Disposition
Estimated $--- mil per asset/yr

Estimated $---k per asset/yr

Craft Efficiency
- Time on Tools

Deferment Reduction
Estimated $---mil per asset/yr

Estimated $---k per asset/yr

Total Quantified Benefit s could run in many millions depends on asset size

Thank you.
Questions?