Using BOM’s to Gain Planning & Scheduling

Efficiencies
Jeff Smith
Fairfax Water

Supported by: Produced by:

What We’ll Cover
Overview- Fairfax Water & Presenter background
Key Topic 1 What was our goal?
Key Topic 2 How do BOMs make us more efficient?
Key Topic 3 What was our challenges & solutions?
Key points to Take Home
Questions
About Fairfax Water
Largest water utility in Virginia
Approximately 1.5 million served
AAA bond rating
400 employees
Coverage 400 square miles
PM/MM/PS/FM/FI went live April 1, 2009
One year project
Decided to leave out BOM’s due to time constraints
HR/CCS were implemented before this project
 Presenter Introduction
Jeff Smith’s Bio
22+ years with Fairfax Water
Plant Mechanic
Assistant Plant Maintenance Supervisor
Senior Maintenance Planner/Scheduler
EAM Team Lead during SAP Implementation
EAM Business Process Analyst (current position)
Benefits of Planning Maintenance
Goals:
Materials ordered in advance
The goal is to insure that there is increased maintenance
productivity
Material delays need to be eliminated
Biggest waste of Fairfax Water Maintenance time is running around
looking for parts
Challenges
No information on materials in our legacy CMMS
No integration with warehousing prior to SAP
One plant doesn’t even have a warehouse (currently)
everything is “Just in Time”
The other plant had a non-stock warehouse
Some part information constantly changes
(Electrical and Instrumentation)
Made the unfortunate decision to wait for BOM until
after Go-Live
Challenges Continued
 Planning Efficiencies using BOM’s
BOM’s are a critical tool for efficient planning
 SAP provides very good BOM functionality:
 Functional Location BOM – Tied directly to a F/L (IB11)
 Equipment BOM – Tied directly to Equipment (IB01)
 Construction Type BOM’s – (CS01)
Links multiple equipment to single BOM
 BOM’s can include Stock and Non-Stock Items
 BOM’s are easily accessible from work orders
Steps to Succeed

Any part on a PM task list was starting point for

Equipment BOM’s
Any part ordered twice had to be entered in the
Material Master, then work center
(Planner/Supervisor) had to create the BOM
Some work centers just pulled the BOMs from
critical equipment and formatted to our MM
nomenclature, then built BOMs
 Steps to Succeed

Make use of Maintenance Assemblies (Material

BOMs) on the equipment that are alike

Feed back from the mechanics, electricians, and

technicians on work orders (still is a challenge)

But now end users see the benefit

Bills of Material Example
Types of BOMs
Equipment Construction type
BOM BOM

Equipment  Equipment  Equipment  Equipment 

Construction
type
Mat 1 Mat 3
Mat 2 Mat 6
Mat 20
Mat 7

Mat 10
Mat 11
 Types of BOMs

Equipment and Functional Locations BOMs are useful for

unique Equipment
Maintenance Assemblies should be used for like equipment
Material Type IBAU
Assign the Maintenance Assembly to Construction type field in the
Equipment record
Also can assign the Assembly to a Task List
How to use BOMs on work orders
 How to use BOMs on work orders

Select the Materials you want

 Select all by holding down the Shift Key as you select
 Select one at a time by holding down the Control key as you click on
each item
Select Choose
How to use BOMs on work orders
Bills of Material- Work Order
 Bills of Material- Work Order
So with this functionality you can have a basic
work order planned with labor & materials in a
matter of minutes
To do this we needed everyone’s input for every
material you use on an order
No free texting, no P-card, no blankets
The more you use the system the better you make it!
 ROI

Savings
 A planned and scheduled job may be completed at ½ to ¼ the
cost of a job performed on a breakdown or emergency mode.

 The important point:

You cannot schedule what you don’t plan
Without good planning, the benefit of planning is lost
Without good scheduling, the benefit of planning is lost.
Bills of Material Created (@ Go-Live)
2,500

2,000

1,500
Equip BOMs

FLOC BOMs

1,000 Assemblies

500

0
171-01 4000 526-01 526-03 721-01 723-01 728-01 729-01
 Bills of Material Created (Post Go-Live)
2,500

2,000

1,500
Equip BOMs

FLOC BOMs

1,000 Assemblies

500

0
171-01 4000 526-01 526-03 721-01 723-01 728-01 729-01
Is this a coincidence?
 Is this a coincidence?
 Work Center 723-01 backlog has been reduced by over 2,000
planned hours (close to half of what it was Sept 2011)

 Work Center 723-01 has created close to 2,500 BOMs

 The closes work center has created over 500 BOMs

Material Master (MM) Benefits
With the
use of the MM
(i.e. MB51) we
can see all the
materials
issued and
now we make
an educated
decision what
to make stock
Key Points to take home

Plan and Schedule work orders (parts in the Material

Master)
Get your BOMs built
Don’t wait, Do it now
Use Maintenance Assemblies when you have like
equipment (Material Type IBAU)
Get buy in and feedback from your workers
Key Points to take home
Once you show the end users how the BOM
functionality works, you win!
Train the workers how to use BOM and get MM updated
(stress feedback)
An added benefit because we are using the Material
Master we now have a tool to make decisions on the
following:
What to stock
What not to stock
 Jeff Smith
Fairfax Water
jsmith@fairfaxwater.org

Supported by: Produced by: