The SAP Enterprise Asset
Management encompasses the overall scope of maintenance procedures and
functions for an organization. The subcomponents of the EAM includes
Breakdown Maintenance, preventive maintenance, corrective maintenance,
work orders/notifications, management of technical objects &
work clearance management.
Work Clearance Management is the process of ensuring safe conditions for personnel and asset while performing maintenance work and controlled testing.
Benefits of the WCM module
- Work Permit / Work Clearance Management helps to manage potentially hazardous routine and non-routine work activities and to improve workplace safety performance.
- Improved collaboration of all involved roles/departments (e.g. maintenance, operations, HSE function) with workflow support for work permit applications and approvals
- Complete integration into SAP EAM maintenance order cycle.
- Flexible definition of different types of Work Permits (configuration)
- Temporal control of Work Permits
- Flexible approval process with different levels of approvals
- Providing best practice approach of integrated process for plant maintenance, work permit management and lockout/tagout based on one set of common master data
- Ensure internal/external safety standards and compliance
- Prevent incidents and damages to the plant and losses of production by ensuring that risks involved in any work are clearly understood and managed
- Cost reduction by process efficiency
WCM process contains 8 main phases. On the day to day activities, one or some of the 8 principal scenario can be run throughout the phase 2 to the phase 8.
Phase 1: Define Safety Libraries (Master Data)
Phase 2: Create Request for Permit (WCA)
Phase 3: Permit Review and prepare isolations (WCD)
Phase 4: Tagging and issue Work Permit
Phase 5: Work Permit Extension (Optional)
Phase 6: Test Run (Temporary Untagging)
Phase 7: Work Permit Closure
Phase 8: Untagging and closure of WCD
This phase consists of preparing master data for WCM: Isolation Points and WCD-Ts. The Equipment category and Functional Location category are the same as decided in PM.
Some of the Equipments that are created for PM (i.e. used as reference object in the Work Order) can be also Isolation Point for WCM. Therefore, they can be reused in the line item of a WCD.
All the other isolation points
which is not relevant for PM will be also created as Equipment. They
will be installed in the relevant Functional Locations (or superior
Equipments) like it will be done for a normal Equipment.
Example: MCB is an electrical Isolation Point for which no maintenance is done because it is mostly a material and directly replaced by a new one issued from the storage location when broken.
Conflict checks are performed
automatically to ensure the consistency of isolation for safety reason
at the time of processing Lockout/Tagout, the external conflict is
checked within the same operational group Electrical or Mechanical.
Therefore, assigning isolation points to either Mechanical or
Electrical operational class is required to ensure the efficiency of
the check. Operational class and operational group are two technical
words but have the same business meaning.
This assignment works for a list of Equipments and Functional Locations. It will be mostly done once a time before the GO-LIVE: a list of Electrical Isolation Points and a list of Mechanical Isolation Points are needed.
WCD-Ts are reusable model of isolation that can be used as reference when creating WCD-O by copy. The following relevant information are available in a WCD-T:
- At Header Level:
- WCD-T Number: it can be internal or external with maximum of 12 characters. If external numbering is used to keep the existing number of the Isolation procedure, then it should be prefixed by WC.
- Short description of the isolation and long description to put more details if necessary.
- Validity dates: it is per default set to 5 years.
NOTE: There is no automatic warning or blocking based on the validity dates of WCD-T, it is an information only. The default duration of 5 years is useful as a "Review of Safety Procedure" (including Isolation Templates) is done in the Industry more or less on this frequency.
- Reference object: Functional Location and Equipment(s) in the object list.
The reference object is a relevant criteria in the List Editing of WCD-Ts when searching applicable template that covers the safety requirements at the time of creating a WCD-O from a WCA.
- Planner group for entering whose planner in the Operation Department is in charge of the template.
- Work center for entering a default value of whose group of local operator in the Operation Department will be in charge of the execution of the Lockout/Tagout at the time of converting this WCD-T to a WCD-O.
- Instruction for the Tagging phase (isolation execution) via long description if necessary.
- Instruction for the Untagging phase (removal of isolation) via long description if necessary.
- Status and traffic light.
- At Item Level:
- Category of item (F Functional Location or E Equipment)
- Technical object of the isolation point (Functional Location label or Equipment number)
- Operational group: Mechanic or Electric
- Tagging condition with a predefined list
- Tagging sequence
- Untagging condition with a predefined list
- Untagging sequence
- Switching Location with free text
- Status on the item level.
Isolation points in the WCD can be only either Functional Location or Equipment in order to ensure the unicity i.e. "1 physical isolation point = 1 isolation point in the System" and permit the efficiency of the conflict checks in the System.
A WCD-T can be only used as
reference when it has been approved (i.e. green traffic light.
Hereby is the life cycle of the WCD-T: