Scribd
Upload
212 views22 pages

Data Quality Taxonomy & Failure Coding

Owens Corning implemented a new failure coding taxonomy and structure in their SAP system to standardize asset and failure data. They worked with Meridium to develop a catalog profile numbering convention, master library concept, and SAP customization. This improved data quality, increased craft efficiency, optimized code selection, and reduced input errors. It also provided benefits like assuring data quality and increasing reliability insights. The project required change management processes, training, and ongoing code development and maintenance.

Uploaded by

Ranjan Shankar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
212 views22 pages

Data Quality Taxonomy & Failure Coding

Owens Corning implemented a new failure coding taxonomy and structure in their SAP system to standardize asset and failure data. They worked with Meridium to develop a catalog profile numbering convention, master library concept, and SAP customization. This improved data quality, increased craft efficiency, optimized code selection, and reduced input errors. It also provided benefits like assuring data quality and increasing reliability insights. The project required change management processes, training, and ongoing code development and maintenance.

Uploaded by

Ranjan Shankar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 22

Data Quality Taxonomy & Failure Coding

Structure at Owens Corning


Brian Gilson CMRP
Lead Reliability Project Manager

Ralph Hanneman CMRP


Senior Consultant

Produced by:

Supported by:

Owens Corning - Who we are


Founded in 1938, an industry leader in glass fiber insulation,
roofing, asphalt, and glass fiber reinforcements
NYSE: OC
2011 sales: $5.3 billion
15,000 employees in 28 countries
FORTUNE 500 company for 58 consecutive years
Component of the Dow Jones Sustainability World Index
Three powerful businesses, three valuable franchises

Composites
Roofing
Insulation

Meridium - Who we are

Global leader in APM software and services for asset-intensive

industries
Lowers the risk of harm to people, our planet and profits
by predicting and preventing physical asset failures
Headquartered in Roanoke, VA
Offices in Houston, Dubai, Bangalore, Madrid, Singapore, Perth, and
Porto Alegre, Brazil
www.meridium.com

Introduction
Owens Corning
o
o
o

On a journey towards mature manufacturing reliability practices


Implementing ECC 6.0 EP4 in North America
Realized Failure Coding in SAP is vital for data driven decisions

No one right way to develop failure coding


Find what works best for your company!

Our intent is to share our story to help others towards


increased reliability of their assets & processes

Where we were
Multiple versions of SAP
No standard work management process

No asset classification data being used


One size fits all failure coding not working well

Taxonomy classification virtually non-existent


Standardization needed to occur
Processes needed to change

Makeover Opportunity
Migration from R/3 3.1i and 4.7 to ECC 6.0

SAP Plant Maintenance Enterprise Solutions


o

Owned by Owens Corning MRG (Manufacturing Reliability Group)

Objectives:
o
o
o
o
o

Enterprise wide solutions


Continuous Improvement (CI)
Data quality and user friendliness
Change management practices and training
Cost effective

The journey
Thoughts to Action
o
o
o
o
o

Discovery process to develop strategy and roadmap


Selected Meridium - failure coding
Developed catalog profile numbering convention
Master Library Concept
Meridium SAP enhancement code

Initial Coding Kickoff Workshop Oct 2011


o
o
o
o

Meridium and OCs MRG team


Utilized Meridium and industry best practices
Modeled after ISO 14224-2006 Standard
Brainstormed taxonomy design for RWP & SAP

The journey (cont)


General Assets and Codes Identified
o
o
o
o

Core team site representatives from all businesses


Kickoff workshop set process
Asset list identified and assigned catalog profile codes
Developed failure coding

Specific Assets and Codes Being Developed


o
o
o
o

Team formed from single business


Kickoff workshop - same process as core team
Assets specific to business identified - assigned catalog profiles
Sanctions additional General assets & codes

Failure Coding Mismatches


A common problem
No methodology to simplify and segregate codes for specific
asset class and types

Matching Damage codes to the Object Part codes error


potential

Failure Coding Mismatch Solution


Catalog Profile
o Unique numbering convention of assets

The Master Library Concept


o Object parts (maintainable items) specific to the asset
o Damage code set specific to object part (maintainable items)

SAP Enhancement
o Automatic matching of Object Part code and Damage code group

Catalog Profile Code


Numerical Design

Enables:
Master Library concept
o Asset classification and Meridiums best practice
o Use of single field
o Easily searchable
o

Master Library & SAP Customization

Brainstormed during
initial workshop.
Developed by
Meridium on top of
the Master Library
Concept

Benefits
Assures data quality
Increases craft efficiency
Optimizes code selection
Reduces craft input errors
Standardizes analysis, reporting and metrics

Challenges
Change management processes and training

Staying evergreen
SAP implementation schedule
Adapting to inconsistency of master data

Enablers
MRG ownership
Investment in the resources
Meridiums training and facilitation
Meridiums proprietary failure coding tool & database

Brian Gilson and Ralph Hanneman

Seeing results

Code Set

Quantity of Codes
developed through
Jan 2013

Detection Method

Functional Failure

19

Catalog Profiles
(Asset Types)

87

Unique Object Parts

139

Total Object Parts


Assigned to Assets

4127

Unique Damages

35

Total Damages
Assigned to Object Parts

1394

Functional Loss

Maintenance Activity

18

Cause Codes

19

Code Groups

236

Positive feedback
User adoption
Committed people
Code mismatch errors eliminated

Moving Forward
MRG Team responsible for MOC process
Specific asset code development
Ongoing monthly transports

Key Lessons & Takeaways


Invest in teams to obtain user adoption and maximize
brainstorming of ideas and codes

Standardized asset classification for category, class & type


(catalog profile)

Utilization of master library concept reduces code selection errors


and optimizes craft activity reporting time

Use the methodology and processes to develop profile and failure


coding as your company requires
Leverage existing standards Dont reinvent the wheel
o Do whats best for your company
o

Q&A

Appendix 1- Mapping Table


Mapping table showing ISO terms to SAP terms with technical information
ISO 14224 Term

SAP Term

Data Entry Method / Options

Technical

Malfunction

Breakdown Indicator

Checkbox

Field name: MSAUS

Detection Method

Not in Standard SAP

Subject / Coding Field

Option: Use Catalog: D - Coding

Failure Mode (Functional Failure)

Not in Standard SAP

Subject / Coding Field

Option: Use Catalog: D - Coding

Effect

Effects on Operating Function

Selection List

Field name: AUSWK T-code OIMW

Functional Loss

(Notification) System Condition

Selection List

Field name: ANLZN T-code OIMZ

Maintainable Item

Object Part

Catalog Code

Catalog B: Object Parts

Condition

Damage

Catalog Code

Catalog C: Overview of Damages

Failure Cause

Cause Code

Catalog Code

Catalog 5: Causes

Activity

Activity

Catalog Code

Catalog A: Activities

Task

Task

Catalog Code

Catalog 2: Tasks

Appendix 2- Master Library Concept


The Master Library Concept
Guidelines
o

Each code used, has a prefix that matched the catalog it is used in

Each code is used to uniquely describe the part, condition, cause, etc.

All Maintainable Items begin with Bxxx, because the Maintainable Items in
SAP are found in Catalog B.
There is only one code for Bearing, not a scattering of codes that mean
bearing.

The code group for damages is the same as the maintainable item code
that the damages are documenting.

Bearing is B001 the code group for Damages for a Bearing is B001.
The actual Damage codes in code group have the prefix C.

E.g. C008 Corroded, C023 Seized, etc.

This way a technician can more easily select the damage codes based on the
maintainable item that experienced the failure

Appendix 3- Whitepapers
Useful whitepapers on the topic of failure coding in SAP
o
o

Meridium Basics Failure Event Coding


https://www.meridium.com/knowledgecenter/members/apmadvisor/basic_failure_
event_coding.asp

Eight Steps to Boost User Adoption of Failure Event Codes


o http://www.apmadvisor.com/archivearticle.asp?id=129&is=23&ord=2
o

How to Easily Use SAP Notifications to Document Crucial Failure Related


Information
http://www.apmadvisor.com/archivearticle.asp?id=223&is=43&ord=2

Brian Gilson, CMRP


Lead Reliability Project Manager
Owens Corning Sales, LLC
[email protected]

Ralph Hanneman, CMRP


Sr. Consultant
Meridium, Inc.
[email protected]

Produced by:

Supported by:

You might also like