Ahmed Abdulrahim Abuouf*, Khalid Mohamed Al Habib**
*Saline Water Conversion Coropration, Saudi Arabia, aabuouf@swcc.gov.sa
**Water Transmission and Technologies Co., Saudi Arabia, kalhabib@wttco.com
Abstract #
The purpose of this paper is to discuss the method of data integration between the AKZ numbering and classification system; “Plant Equipment Coding”, and MESC; Material and Equipment Standard Code, for spare parts. The new results achieved is more cost computing accuracy and precision. In conclusion, there two method; method one for existing plant and method two for new plant construction and both of the methods are important to be implemented on enterprise resource planning system in the seawater desalination sector for better cost computing precision.
Keywords: Data Integration, Plant Equipment’s, Spare Parts
Acknowledgment #
Full regards and appreciation to Professor Salih Duffuaa and Professor Shokri Selim from the department of Industrial Engineering in the university of King Fahad Univesity for Petroleum and Minerals for their vital contribution and support to complete this paper, towards boost the industrial sector in applying cost management and control.
1 Introduction #
1.1 Brief
In order to have better control of the cost on the plant, you need to précised computing of the cost. Data integration between the equipment in the plant and its spare parts will be of much help in this. However, this is not achieved in practice due to separate system of coding. The equipment coding in the plant is following AKZ numbering and classification system, whereas, the spare parts coding is following MESC material and equipment standard code.
1.2 Problem Definition
There are two methods; method one is for the existing plants, and method two is for the new plants construction, and both of the methods are important to be implemented on enterprise resource planning system in the seawater desalination sector for better cost computing precision.
1.3 Objective
The purpose of this paper is to discuss the method of data integration between the AKZ numbering and classification system; “Plant Equipment Coding”, and MESC; Material and Equipment Standard Code, for spare parts
1.4 Proposed Solution
The suggested method is to do data normalization for existing data to have a system of data integration for new data when constructing a new plant.
1.5 Alternative
Many IT company have tried many methods to fix this problem but it was not having a remarkable achievement due to the complexity of the data integration of the existing data and at the end relied on the experience of the employee who is working on the plant.
1.6 Evaluation
The new results will be achieved is more cost computing accuracy and precision due to the data link between the equipment and the spares in the plant.
2 Background #
Figure 1 AKZ Classification System [3].
The plant designation system AKZ is a predecessor system for identifying plants, systems, sub-systems, and equipment items for plant operating companies. The implementation of AKZ is formalized by commonly known regulations. The system categorization identifies entire machinery in a plant, from the smallest electronic component to the largest turbo-alternator. It also covers the buildings and structures. equipment is broken down into a number of levels. nomenclature structure.
The MESC – Material and Equipment Standards and Code, is the cumulative development from idea born on October 1932, when it was recognized that a system was required whereby materials from various manufacturers and countries specified to different national standards, could be readily compared, identified and administrated. Moreover, national standards did not exist for many articles used by the companies and own standards had to be established to ensure safe and efficient operations. These were the basic ideas on which the concept of the MESC was based [1].
MESC comprises three kinds of document:
The “CODING SCHDULE”; which provide the common framework for coding of any item used in the company. It specifies the relevant group sub-group and/or sub-sub-group, viz.: the first 4 or 6 figure of a ten-figure code number.
The “CATALOGUE”; which show buying descriptions, units of measure and illustrations of selected materials and equipment together with their ten-figure code numbers.
The “GENERAL INDEX TO MESC”; which is a list, in alphabetical sequence, all materials and equipment recorded in the “Coding Schedule” and “Catalogue” and refer to the first 4 or 6 figures of the ten-figure code numbers.
The “General Index to MESC” is developed by SHELL INTERNATIONALE PETROLEUM MAATSCHAPPIJ B.V. [1]
3 Methodology #
Figure 2 Data Integration of AKZ Classification System with the MESC and One-to-One Database Relationship
First of all, the idea of integrating plant equipment’s coding system to its crossponding material and spare parts, it looks simple from the first looking point, however, when you go into practice and to the deep details of the process, it looks not easy. From Information Technology point of view; it is only mater of establishing One-to-One database relationship. However, the table primary key’s of the AKZ classification system is different from the table primary key’s of the MESC. Thus, you endup with many-to-many database relationship instead of One-to-One database relationship. Next, we do have two types of plants; (1) existing plants and (2) new plants. For every type we need to establish a method of creating database
relationship between its AKZ System and its MESC System. Then, for the newplant, we need to track the database relation creation from the early stage of the plant creation project. Whereas, for the existing plant, practicly, it is done through the maintenance and operation people experience to establish the database relationship with the help of the IT people. This is done through, the maintenance people start to code the spare parts of the equipment by the time when the plant is in operation. In Fact, there is a real need to establish a standard policy and procedure to qurantee early database relationship establishment.
At the beging, we need a system that track and document the creation of the plant from its early stage; asset-by-asset.
Also, nowadays, there are many companies for building Enterprise Resource Project such as Oracle and SAP had succeeded in developing ERP systems that cover many aspects of the investment projects. Then, Which all covers the life cycle of the assets and could suite the implementation of Data Integration. In Conclusion, Enterprise Asset Management enables the customer to Support compliance and corporate governance with an enterprise perspective.
4 Discussion
At the beging, the plant operator should co-operate with the designer/manufacturer/installer in a full analysis of its reliability, maintainability and safety characteristics. Such a ‘plant procurement’ exercise should include assessment of spare-part provisioning, of maintenance personnel training and of supplier support systems. The higher the potential costs of maintenance and unavailability the more vital is this exercise. Also, Decisions to buy new or replacement equipment should be based on a present-value life-cycle analysis of costs. Such an analysis must take into consideration both maintenance and unavailability costs — these being estimated, wherever possible, from documented experience. Then, The plant operator and supplier should co-operate in the collection and analysis of plant failure and maintenance data in order to identify maintenance problem areas and to determine the plant’s optimum maintenance operation. Since the design of equipment is a continuing process, information thus gathered should, ideally, be continuously fed back to the equipment manufacturer, and in certain circumstances to a data bank, which could be shared on an intercompany, national or international basis. The difficulties of these last operations continue to pose a major obstacle to the successful implementation of a data integration approach, communication systems are expensive and different organizations (with different objectives) are involved during the equipment life cycle [4]. In Conclusion, we need a system that track and document the creation of the plant from its early stage; asset-by-asset.
5 Results #
At the beging, there two methods for applying cost accounting; one, applying cost accounting on your process, two, applying cost accounting on your activities. Also, the more you apply cost accounting on your system, the more accurate and precise your results. Then, the vital of data integration between your plant equipment’s coding system and the spare parts and materials coding system of the plant. In addition, from quality control point of view, in order to control and identify the losses in your plant process and activity , you need to track the higher part of your plant that is producing failures in system. In Conclusion, having a system of data integration between the AKZ Classification System and the MESC is must not a luxury.
6 Conclusions #
In order to have better control of the cost on the plant, you need to précised computing of the cost. Data integration between the equipment in the plant and its spare parts will be of much help in this. However, this is not achieved in practice due to separate system of coding. The equipment coding in the plant is following AKZ numbering and classification system, whereas, the spare parts coding is following MESC material and equipment standard code. There are two methods; method one is for the existing plants, and method two is for the new plants construction, and both of the methods are important to be implemented on enterprise resource planning system in the seawater desalination sector for better cost computing precision.
The purpose of this paper is to discuss the method of data integration between the AKZ numbering and classification system; “Plant Equipment Coding”, and MESC; Material and Equipment Standard Code, for spare parts. The suggested method is to do data normalization for existing data to have a system of data integration for new data when constructing a new plant. Many IT company have tried many methods to fix this problem but it was not having a remarkable achievement due to the complexity of the data integration of the existing data and at the end relied on the experience of the employee who is working on the plant. The new results will be achieved is more cost computing accuracy and precision due to the data link between the equipment and the spares in the plant.
References #
- “General Index to MESC”, SHELL INTERNATIONALE PETROLEUM MAATSCHAPPIJ B.V., 1979
- Abuouf, M ,Al-Habbib, K,” GOVERNING AND OP?TIMIZIN?G BUSINESS IN THE SEAWATER DESALINATION SECTOR THROUGH TEROTECHNOLGY”, The International Desalination Association World Congress on Desalination and Water Reuse 2015/San Diego, CA, USA
- Anlagenkennzeichnungssystem (AKS oder AKZ),Wikipedia, https://de.wikipedia.org/wiki/Anlagenkennzeichnungssystem
- Anthony Kelly, “Strategic Maintenance Planning” , Butterworth-Heinemann, 2006-06-28, ISBN: 0750669926, 304 pages
