|
System Dynamics’ implementation of Maximo Work Order Processing
as a Paperless System
Schering-Plough (Avondale) Company (SPAC) is a Pharmaceutical
API Manufacturing Plant based in Rathdrum, Co. Wicklow, Ireland. SPAC
use IBM Maximo as part of their Maintenance Management Process. As
SPAC is regulated by the IMB and FDA, Maximo is a validated System.
The Challenge
In 2004, System Dynamics installed Maximo in SPAC, replacing their
legacy, AS400-based Maintenance Management System, Maintracker. The
project required compliance with regulatory requirements (FDA /
IMB) and included Data Migration from Maintracker, Maximo installation
and customisation and training, all under the Schering-Plough System
Development Lifecycle.
Up to 2007, Maximo printed Work Orders and any attached Maintenance Work Instructions (MWI)
for all Preventative Maintenance (PM) and Corrective Maintenance (CM) Work Orders. The
completed signed Work Orders were retained as the record of note. This
involved scanning and verifying the completed manual Work Orders to their Document
Management System (Zyimage).
The challenge for SPAC was to remove the dependency on scanned paper records
as part of the Work Order Processing. Validation was required under the
Schering-Plough World Wide Quality Standard as Work Order Processing / Preventative
Maintenance is a critical process for FDA / IMB compliance.
The Approach
System Dynamics worked with Engineering, Maintenance, Validation
and Information Systems Departments within SPAC.
The requirements, design, development and testing phases were undertaken, followed
by extensive Validation testing to formally test the changes. This consisted
of an Installation Verification (IV) for Configuration changes and a Functional
Verification (FV) for the new process / screens / reports / document attachment
processes.
Throughout the process, the existing Requirements Traceability Matrix (RTM) was
updated to reflect the validation of new requirements identified within the URS.
The Solution
By extending the use of Maximo, all Users now interact directly
with the electronic Work Order:
- Craft Coordinators use a new report to assign Craft(s) to the
Work Order and to inform the Craft(s) of the Work Orders assigned.
- Crafts review the electronic Work Order.
- Crafts update details directly to the electronic Work Order.
- Craft Coordinators / Engineering Planning review completed
Work Orders and add additional comments if necessary.
New Training Modules were developed for all users to provide training
in the following:
- Crafts direct interaction with Maximo, to enter work details.
- Attachment of MWI documents and Service Receipts to Work Orders
by Crafts and Craft Coordinators.
- Checking of the content of the completed work, closing of Work
Orders and tracking of Work Orders for Craft Coordinators and
Engineering Planning.
The Benefits
The implementation of Maximo Work Order Processing as a Paperless
System has provided SPAC many immediate and long-term benefits
including:
- Maximo becomes the Record of Note for Work Orders carried out
by the Maintenance Department, replacing Zyimage.
- All relevant information including Labour and Materials are
recorded directly to Maximo. Where MWIs need to be printed
and annotated, the printing is controlled and the documents are
attached directly to the relevant Work Order.
- Removal of printing of Work Orders and MWIs provided a direct
cost-saving.
- Users interact directly with the Work Order. Maximo
controls the information entered to ensure that it is valid and
accurate.
- Administrative Staff no longer need to scan all completed Work
Orders into Zyimage.
|
