corrective orders
DESCRIPTION
SAP Order AnalysisTRANSCRIPT
STONEWALL SNAPSHOT – REACTIVE ORDERSSTONEWALL SNAPSHOT – REACTIVE 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
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.
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
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
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
$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
$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
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
$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
$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
$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
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
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
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.
‘Out of the Box’ SAP allowed for greater granularity in Notification Types, allowing for true data analysis of Corrective
Maintenance related to Equipment Malfunctions