corrective orders

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STONEWALL SNAPSHOT – REACTIVE ORDERS STONEWALL SNAPSHOT – REACTIVE ORDERS

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SAP Order Analysis

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Page 1: Corrective Orders

STONEWALL SNAPSHOT – REACTIVE ORDERSSTONEWALL SNAPSHOT – REACTIVE ORDERS

Page 2: Corrective Orders

0

100

200

300

400

500

600W

ILL

PR

ES

ME

LE

ND

RA

WA

LD

EN

R

CO

WG

ER

K

RA

YM

ICH

OV

ER

KO

TT

FE

RR

IER

R

DA

LL

AS

W

TU

RN

ER

WA

LD

RO

PF

CO

ME

RG

MC

DA

NIE

M

EP

PA

RD

JR

TU

TW

ILE

D

HU

MM

EL

M

SE

AL

CH

CO

OK

SC

WIL

JAM

EE

SH

AN

KD

KIT

ED

BA

RE

GR

BA

UG

HE

DO

JOY

PA

RK

L

HE

PN

ER

J

CO

ME

RM

DO

VE

PE

NN

SAP M2 Notifications by Initiator - YTD

Page 3: Corrective Orders

Count of SAP Corrective Orders by Priority - YTD

231

2043

554

946

2642

1st Available Outage

Schedule Within 1 Mo

Schedule Within 1 Wk

Start Within 48 Hrs

Start Immediately

“REACTIVE”

Planning Indicator Orders

Unplanned 2501

Planned 21

Immediate 1066But...Planning Indicator shows only 1066 as Immediate.

Page 4: Corrective Orders

Priority 0 -1 Corrective Orders by Notification Codes

11

1370

5

49

960

21

76

560

184

337

Cosmetic/Work Cond

Normal Maint/C Safety

Cost Red Work

B Safety, No Immed Threat

Correct Maint, Req Shutdown

Minor Q and E Impact

Prev Maint

Throughput, Reduced Prod

Q and E Compliance

A Safety/Breakdown

Should Indicate Notification Priority

Page 5: Corrective Orders

Utilization of the Notification Status Codes (M2)

Status Description Corrective Notifications

03 101 Safety-Personnel 76

03 101 201 Safety/Safety 2

03 101 201 301 Safety/Safety/Env 1

03 201 Safety-Site 5

03 301 Environmental 13

03 401 GxP 22

03 None Checked 7361

Page 6: Corrective Orders

SAP Labor Hours by Work Type - YTD

67%

15%

1%

13%4%

PM01 PM02 PM03 PM05 PM06

Start Immediately 13,070Schedule Within 1 Mo 9,815Start Within 48 Hrs 5,190Schedule Within 1 Wk 4,861Standing / Blanket 2,4741st Available Outage 1,540System Generated 32Annual Outage 0

Page 7: Corrective Orders

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000F

2

FIN

AB

F1

F7

F8

UT

IL

SD F6

F5

WT

QO

PS F9

HP

V P

UR

F4

MM

GM

T

AD

MIN

TE

CH

OP

S

MA

INT

HP

VA

LU

M

BL

AN

K

EN

VIR

/SA

F

Reactive Maintenance Cost by Plant Section - YTD

Mat'l Costs

Hrs x $75

Page 8: Corrective Orders

$0

$100,000

$200,000

$300,000

$400,000

$500,000

$600,000TO

FLO

CVESSEL

/ TANK

PUMP

CAPPER

MIX

ER, AG

ITATO

RCO

LUM

NFI

LLER

CHILLE

RSTE

RILIZ

ERAIR

HANDLER

CENTRIF

UGE

HEAT EXCHANGER

Reactive Maintenance Cost by Class - YTD

Mat'l Cost

Hrs x $75

Page 9: Corrective Orders

Reactive Orders to FLOCS by Cost

$18,520

$15,799

$13,413

$11,759

$10,827

$9,520

$9,449

$7,846

$7,614

$7,447

$7,417

$32,977

FINISHED ANTIBIOTICS, STERILE FILLING

82CL9750SYS, CL9750F8, COLUMN 9750 SYS

FIRST FLOOR, BLDG 21

81OV402, FEDEGARI DRY HEAT STERILIZER

9420 CONDENSERS SYSTEM

81HBLENDING, BUILDING 81 BLENDING

SD COMPRESSION, MODULE 1

SD, PKG LOWER

81CMI855, CILASTATIN MILL MI-855

IMA FILLING LINE, STERILE FILLING

BLDG 81 AB, BULK ANTIBIOTIC

YARD, BLDG 80

Page 10: Corrective Orders

$0

$10,000

$20,000

$30,000

$40,000

$50,000

$60,000

$70,000

$80,000

TO F

LOC

CAPPER

FILLE

R

STERILIZ

ER

INSPECT M

ACHINE

WASHER, B

OTTLE

LABELER

THERMO

FORM

SORTER

LIFT

FINAB Reactive Maintenance Cost by Class - YTD

Mat'l Cost

Hrs x $75

Page 11: Corrective Orders

$0

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

$160,000

VESSEL / T

ANK

TO FLO

C

PUMP

CENTRIFUGE

DRYER, ROTARY

SCRUBBER

INSTR

INSTR

, FLO

WM

TR

OXIDIZ

ER

INSTR

, LEVEL

INSTR

, GAS D

ET

F2 Reactive Maintenance Cost by Class - YTD

Mat'l Cost

Hrs x $75

Page 12: Corrective Orders

$0

$10,000

$20,000

$30,000

$40,000

$50,000

$60,000

$70,000

1007

2440

1009

0163

1007

2244

1008

9787

1007

2083

1009

0043

1007

7319

1007

2320

1008

1201

1007

2125

1009

0447

F2 Vessel Reactive Corrective Cost by Equipment

21CTA2606SYS (Montelukast Mechanical Setup Spring 2010)

21CR1281, CRYSTALIZER, CR1281

Page 13: Corrective Orders

0

2

4

6

8

10

12

14

Co

un

t o

f O

rde

rs

1009

0163

1008

9945

1007

2244

1008

9787

1007

2277

1007

2226

1008

9905

1007

2320

1007

2199

1007

2083

1009

0043

F2 Vessel Reactive Corrective Orders by Equipment Number

21CR1281, CRYSTALIZER, CR1281

Page 14: Corrective Orders

replace bottom valve hs 1281-01 CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

change out EM flushing filter CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

install sprayball CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

Remove and replace cloth on EM flush1281 CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

Remov sprayball at CR-1281 CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

Fabricate two arms for docking valve CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

change out EM flushing filter CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

change EM flush filter CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

bottom valve SP will not match PV CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

replace EM flush filter CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

Install sanitary fittings at CR-1281 CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

replace EM flush filter CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

tighten sown manway CO-C-B-T-CR00 21CR1281, CRYSTALIZER, CR1281

Page 15: Corrective Orders

Continued Challenges

• Still writing Notifications to FLOCS• Better use of Order Priority and Notification

Codes• Better use of Failure Codes• Improve use of Status Check Boxes (GxP)• Still Have Orders TECO’d with Zero Hours and

Zero Materials• Difficult to Separate True Corrective

Maintenance from Requests and Orders for P.O.

Page 16: Corrective Orders

‘Out of the Box’ SAP allowed for greater granularity in Notification Types, allowing for true data analysis of Corrective

Maintenance related to Equipment Malfunctions