Transcript Application of the SOS methodology to new plant

SOS in Greenfield sites and
SOS as applied to
Manufacturers Spares Lists
Hydro Quebec
• SOS applied to spares lists for new high
voltage transmission equipment
• Immediate saving - $795,000
• Total list $2.2million
WMC St Ives Gold
• SOS applied to manufacturers’ spares
lists
• Immediate benefits, one site, one list
over $120,000
New Zealand Aluminium
• SOS applied to spares list for new pot
line
• Immediate benefit - $700,000 savings on
list worth $1.4million
Delta Electricity
• SOS applied to spares for new Ash plant
• Original list over $900,000
• Eventual purchases less than $100,000
• - ref Peter Reed at Wallerawang Power
Station
Queensland Nitrates
• Greenfield site - new spares lists
• Lists totalled $2.49 million
• SOS optimized lists valued at $ 1.25
million
• Saving $ 1.24 million
• See the following slides for a report
Specific Application of the
SOS methodology to new
plant
The Project
• A joint venture between Dyno Nobel and
Wesfarmers CSBP.
• The plant output has two very different
applications.
• Explosives - Dyno Nobel
• Fertilizer - Wesfarmers CSBP
The Assessment
• Greenfield assessment of the running
spares required for the first two years
operation.
• Commissioning spares were the
responsibility of the construction
contractors.
Traditional SOS
• The assessment of existing stores.
• Inventory parameters already known.
• CMMS data is converted to SOS format
for assessment.
• The result is a comparison of the new
purchasing policy.
Greenfield Assessment
• Suppliers must be identified.
• Inventory parameters can then be
sourced.
• Process diagrams aid the assessment.
The Greenfield Plan
• Identify equipment vendors.
• Request inventory data from vendors.
• Use data to perform SOS assessment.
• Produce purchase orders.
• Prepare stock data for upload into CMMS.
• Integrate all this with SOS database
Identifying Equipment
Vendors
• This information is sourced from the
construction contractors.
• A database was compiled of equipment
numbers and vendor contact details.
Inventory data acquisition
• A standard fax or email is sent to all of
the equipment vendors requesting
inventory data.
• Correspondence progress is tracked with
the vendor database.
SOS Assessment
• When the complete information is
received, the standard SOS assessment
can be performed.
• Comparison is drawn between the
vendor’s recommendation and the SOS
accepted max/min.
Stock data upload
• The standard SOS database is able to be
uploaded into the CMMS.
• The spare descriptions can be re-worded
to Auslang specification.