Efficient Shutdown & Turnaround Management at a leading metals manufacturing company with Massetic STOP4

CASE STUDY

Posted on 15 Dec 2020

About Client:

Client is a globally renowned and one of the largest speciality steel manufacturing organization.They have multiple plants across several locations. The client runs S/4 HANA for their business processes.

Business Scenario:

They have several plants across a couple of locations. Their maintenance team runs close to 400+ mini and 50+ major shutdowns every year which last for 2-30 days. All the plant asset information including maintenance history is managed within SAP. For Shutdown management, they had been using multiple tools for planning, execution and reporting. For a few shutdowns spreadsheets were used for planning and execution.

Challenges:

The challenges faced by the organization were

  • Inability to use a single integrated system to cater to all turnaround requirements resulting in frequent slippages in duration and cost escalations
  • Lack of specialized project management methodologies in SAP to manage their turnarounds
  • Unwanted and unforeseen delays in completion of the STO projects
  • Increased cost of STO project
  • The external planning tools had limited information of the assets, material availability and impacted the quality of scope and planning
  • SAP system had limited information on the plan and execution status and slowed down the decision making progress
  • The asset maintenance data in SAP was not complete as all operations were not updated

Solution

Maassetic STOP4 solution was implemented to address the issues of Duration, cost and lack of transparency. The solution is designed & developed with several unique features like:

  • Completely within SAP Leveraging latest UI technologies
  • Interacts with modules like PM, MM, HR seamlessly
  • A powerful Gantt Chart for visual planning and execution tracking
  • Ready reports and dashboards to help take data driven decisions during planning and execution
  • Companion Mobility solution to update activities and issues from the field

Benefits:

  • Reduced duration of both mini and major shutdown projects by upto 15%
  • Overall savings in cost upto 8%
  • Everything in SAP. IT support decreased by more than 50%
  • Systematic improvement of the process from past learnings
  • No duplication of data & processes eliminated data errors and reduced delays
  • Mobile solution supported safe and  agile execution
, Efficient Shutdown & Turnaround Management at a leading metals manufacturing company with Massetic STOP4
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