Maintenance of hydrogen glow discharge via Plant Maintenance

Since early 2000, Corus IJmuiden (now Tata) have converted their full maintenance information system to SAP. Thereafter Corus initiated the introduction of all maintenance activities needing to be carried out on technical installations utilizing the SAP Plant Maintenance Module. Within the context of this project, the maintenance of the hydrogen glow discharge system had to be entered into SAP.

In the early days of SAP this system was applied in different ways within the organisation. It was an approach which eventually resulted in an unworkable situation, since the company had not decided in favour of a uniform structure right from the start.

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Erik Jonker
Consultant SAP PM, Corus, IJmuiden

In order to avoid the same problems with the organisation of the Plant Maintenance module, 7 years ago, I decided to develop a format for the way this module should be structured. It was a format that proved to be essential for introducing the CPP H2 hydrogen glow discharge system in SAP.

Production

Steel firm Corus annually produced over 7 million tons of steel in the form of semi manufactures and end products for the world market. Semi manufactures include hot rolled strips and hot and cold rolled rolls of steel. The processing in the hydrogen glow discharge system of the cold rolled rolls occurs by means of hydrogen in order to upgrade the crystalline structure of the material to an acceptable level for further processing. Coated sheet metal is an example of the end products. The coated metal sheets with a thickness of over 0.5 mm are among others supplied to the sheet metal processing industries, such as the automobile industry, the construction and the installation industries. The thinner sheets are shipped to the can market for the production of tin coated, chrome coated and plastic coated materials. The material is commonly used in the food industry as well as in spray can manufacturing.

Senior Consultant
PDM Rotterdam

Before our people actually became involved in entering the hydrogen glow discharge process into the SAP Plant Maintenance Module, we first formed a team of 12 people, regularly involved in this trajectory, as well as a steering committee. The steering committee consists of e PDM Project Leader, a Technical Project Leader of Corus, an IPA Coordinator, a Maintenance and Information Systems Coordinator and a business contact person. Next, we formulated the assignment in order to properly define the project limits.

Two phases

Once these activities had been completed, PDM became involved by filling the Plant Maintenance-module for 60% in the rest phase of the project. Among other things, we created the job positions as well as the critical articles and the pertaining technical drawings, maintenance regulations and work instructions introduced and linked to the objects in SAP. The eventual completion of the database with the remaining data and the other finishing activities are planned for phase 2. This will be handled by Corus themselves.

Erik Jonker
Consultant SAP PM, Corus, IJmuiden

The hydrogen glow discharge system consists in total of 19 platforms, with 10 furnaces and 9 cooling domes. Since the maintenance activities on the platforms in principle are all the same, we have started to list the activities for one platform. When this has been completed, it is relatively simple to copy this to other platforms. When everything occurs according to the planning then the last 6 platforms will be delivered in November 2009.

Finally

Obtaining the proper information posed the greatest challenge to all parties involved in this project, since much of it had not been recorded on paper anywhere within the company. Instead, it was an integral element of the experience and available know-how of our employees. After many years, this information has now been stored in a system making it is easily accessible to others within the organisation.


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