URS Mobile Integration at TOCDF January 10, 2013 Todd Loveday and Lync Jones
Who is URS? • Employs 50,000 employees in 30 countries • Engineering, Construction, and Technical Services • Serves Federal, State, and Local government agencies, and multinational Fortune 500 Companies. • 10 Billion in yearly revenue • Multiple sites utilizing Maximo • Combination of URS, EG&G and Washington Group International
Who is TOCDF? Tooele Chemical Weapons Disposal Facility • OSHA VPP (Voluntary Protections Program) Star Site • Recordable Injury Rate through December 2012 (RIR) – 0.65 • 15,558,683 man-hours without a lost time accident as of December 31, 2012 • 1214 days without a security violation • Environmental Permit Non-compliance Rate – 0.67 12 month rolling average
Chemical Agents • Deseret Chemical Depot had 43% of the chemical weapons stockpile in United States • Agents GB (Sarin), VX, H (Mustard), GA (Tabun), and L (Lewisite) • GB and VX have long been destroyed • Mustard was completed in the Summer of 2011 • GA/Lewisite was completely destroyed as of January 2012
Our Maximo Setup • We: • Are a 24-7 operation; Four rotating shifts • Plan 300-400 corrective maintenance and 300-400 preventative maintenance work orders per month • Have five schedulers (two per shift) who rotate on days to cover seven days. • Have nine maintenance planners (two per shift plus a day planner) who cover 24-7. • Schedule work a week in advance (meet Thursday for following week) and track closely the number of “emergent” work orders.
Our Maximo Setup • Maximo Support Group consists of: • Project Manager – Plant interface and logistics • System Analyst and Designer – reports, system design, screen setup/configuration • Maximo Administrator – security, application/database configuration, mea/integration framework configuration & setup, screen & workflow configuration • ERP Database Administrator – application & database server setup, patching, tuning and maintenance
Why Did We Upgrade Maximo? • IBM’s announcement of end of service for Maximo v5.2, unless you wanted to pay increased maintenance fees • Version 7 was advertised as more user/administrator/ maintenance friendly • Most third party add-ons are focusing on versions 6 and 7 • Assist other sites across the URS family • Property, inventory, work order data will be needed after plant is shut down (contract, permit closeouts) • Experience for Maximo Group (next assignment)
How We Use Maximo • We love the process control Maximo gives us! • About 10 Major Work Classifications from Work Planning and Control to Condition Reporting (77 total) • Work Planning • Corrective and Preventative Maintenance • Lockout/Tagout • Work Planning Teams • Maintenance, Safety, Quality, Engineering
How We Use Maximo • Support Organizations • Engineering Service Requests • Design • System/Field Engineer logs • Configuration Management • Configuration Change Approvals • Annual Procedure Reviews • A PM for a procedure review • Information Systems Service Requests
How We Use Maximo • Purchasing • PRs created in Maximo • Purchase Order generated in Maximo • PO receipt information flows through “bridge” to Deltek Costpoint. • The system requirement for Maximo version 7 was to perform all purchasing functions in Maximo and only send financial information to Costpoint.
How We Use Maximo • Inventory tracking • Materials received in Maximo • Data flows through “bridge” to Costpoint for payment • Manage reorder levels (min/max) • Track issues, transfers, and receipts • With Maximo 7 we receive to PO’s in Maximo and only send required invoice data to Costpoint
How We Use Maximo • Condition Reporting System • Cause Analysis System (Root and Apparent) • All employees have access to report a condition • Management Assessment System • Peer Observation System • Laboratory Work • Lessons Learned
Why Mobile, what changed? • New Government Contract Property Administrator (CPA) • Applying a different interpretation of the Federal Acquisition Regulations (FAR) • Impending Property Control System Audit (PCSA) • All fifteen functions will be audited at once
Why Mobile? • Possible Inventory inconsistencies identified • Location inconsistencies • Quantity inconsistencies • Issue and Transfer inconsistencies
Why Mobile? • Warehouse inventory requirements • Barcode all inventory item locations in all warehouses • Barcode all inventory items in all warehouses • Complete 100% warehouse inventory using handheld devices updating the Maximorecords through the MBO’s
Why Mobile? • Receiving requirements • Barcode all inventory items upon receipt • Prepare direct deliveries for the Transportation department • Help with issues in relation to direct deliveries performed • Track and trend issues from the Transportation department
Why Mobile? • Property requirements • Perform 100% Asset inventory • Track all Asset moves and Custodian changes • Asset turn-ins upon RIF • Excess Assets after PCARRS review
Why Mobile? • Closure requirements • Disposition all Inventory Items (51424 Items) • Disposition all Assets (50012 Assets) • Some items may be dispositioned in place and moved to the Defense Logistics Agency facility/warehouse at a later date. • Excess Assets after PCARSS (Plant Clearance Automated Reutilization Screening System) review.