P1253296777UwQPJ

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Maximo Implementation at Huntsman, West Footscray
Ganesh Natarajan Asset Reliability Manager Downer
Engineering
Mark Presnell Systems Engineer Huntsman Chemicals
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Huntsman _at_ West Footscray a pen sketch
Chemical manufacturing facility
Monsanto Chemplex - Huntsman
Asprin Agent Orange - Styrene
1940s
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Huntsman _at_ West Footscray a pen sketch
1970s Styrene Plant was built
Present 300 people on site
Classified - Major Hazard Facility
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The Site complexity
Site Demand on CMMS

• 28,000 Equipment items.
• 90,000 Spare Parts items.
• 9,000 Items inventory
• 15,000 PO Lines/Year
• 12,000 Work orders/Year
• 10M Spend/Year

The Interest groups
State of Systems pre-Maximo
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COMPASS Mainframe based legacy CMMS

• Limited functionality limited capability
  limited OEM support.

Huntsman decided to replace COMPASS with MAXIMO
5.2 to

• Demonstrate adequacy of their system to the
  Regulator.

• Introduce best practice Improve productivity
  efficiency.

Appoint Project Manager from Downer, Alliance
Partner
External Resource

• Job Specific Expertise

• Impervious to site dialogue No
  history/relationships/baggage

• Dedicated resource

• Fresh set of eyes site practices

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The Implementation Project
Agree on Project Scope Deliverables
Project Delivery in Multiple Phases.
Phase 1 will
1. Replace COMPASS as is with MAXIMO.
2. Integrate identified Databases into MAXIMO.
Generate Project Plan
3. Introduce Accountability in Work Processes.

• Project over 9 Months
• Sep 04 to May 05
• 4000 man-hours
• 210 Licenses
• 0.5M Software, Service Providers, excl staff

Formulate Project Team

• Formulate Core Team Project Mgr, Systems
  Engineer, Maintenance, Stores, Purchasing

• Representative Interest Groups Team

Justified and Approved
Core Team 5 day Maximo Training Understand
capabilities / functionality of Maximo
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Process Mapping 12 Weeks
Map Current Processes

• Interact with representative Groups
• What do you do?
• How do you do it?
• What do you want from the new CMMS? the wish
  list.

The Guarantee We will consider, we will try, but
no guarantees
Map Proposed Process Core Team
Discuss and gain agreement
Sign-off on proposed process
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Process Mapping Work Management in Compass
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Process Mapping Work Management in MAXIMO
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Process Mapping Work Management in Compass
Raise Work Order approved
Execute Work
Cost Rpt End of Month
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The critical issue
System Implementation Change Management
Change what?
Change current practice to suit System
Change System to suit Current practice

• Culture
• Resistance
• Always done it this way

• Customise System
• Modifications to vanilla

The Risk

• Lose built in best practice
• Lose productivity gains
• Upgrade reimplementation,

• Best practice system not being used
• No uptake back door opens.
• Continued resistance
• Implementation failure

• Eg PO - over the limit.

Strike the right balance for a successful
implementation
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System Development 16 Weeks

• Translate proposed processes

• Screen Changes - JSP
• dB Configuration
• Workflow design and Setup
• Oracle Setup
• Reports development- Actuate
• Data migration Compass Maximo
• Parallel Systems Integration

• Scope System development

• Manage development phase

• Maintain rigorous discipline in tracking and
  managing changes.

Training preparation 6 Weeks

• Formulate User Groups Primary, Secondary,
  Tertiary

• Slot User into Groups

• Develop tailored training packs for each group

• Schedule execute Training 4/5 Cycle operators
  Tertiary(120), Secondary (80), Primary (10).

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Training
Talk it up! Communicate
Entice MAXIMO TRAINING - WIN AN "EXPERIENCE" !!!

• All Successful Trainees enter Draw

• 1 in 4 win "EXPERIENCE Vouchers 50 _at_ 100 each

Training Schedule Training over 4 Weeks
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Go Live
Go Live over Weekend
Go Live Typical issues
On Monday

• Data migration
• Backups
• Trials
• Validation
• Sync Test Prod
• Etc.

Fingers Crossed ?
No Phone Calls!!
Site Rounds by 10am.
Site using Maximo Satisfactorily.
A Happy Ending! Project completed on Time, _at_ 95
of Budget.
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CSF CMMS Implementation

• Management Support

• Map processes gain agreement

• Communicate .. till it hurts

• Customised training

• Strike the right balance System vs Culture change

• 101 Project Management

• Framework Scope Be clear on outcomes

• Team Get the best possible resources

• Scan the horizon..

• Always have a plan B a plan C

• Give it a 110....

If you think success happens by chance, think
again - anonymous
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Any Questions?
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Some Project Highlights

• Process Mapping Active Interaction

• Process Hijack! - Purchasing Eng / RM

• Maximo MSA Interface seamless?

• Rotables Management

• Software Websphere / Weblogic

• IT Interaction

• Restructure Phenol Closure

• WorkSafe Audit during Training