User Manual - Maintainer Maintenance Execution

Maintainer Maintenance Execution User Manual
Date Generated: 28/03/2012
How to Use This Manual ................................................................................................................. 4 Assessments covered in this manual .............................................................................................. 5 Level 1: 305. Work Management ................................................................................................ 6 Level 2: 305.01. Work Strategy Management ........................................................................ 8
Level 3: 305.01.01. Develop Work Strategies ......................................................................................9 Activities .............................................................................................................................................12
Component : Define Work Strategies .............................................................................. 12 Level 3 Metrics ................................................................................................................ 15 Level 2: 305.02. Schedule Management .............................................................................. 16
Level 3: 305.02.01. Report Events and Work Requirements .............................................................20 Activities .............................................................................................................................................21
Component : Event Notification Identification .................................................................. 22 Component : Create Scoped Notification......................................................................... 25 Component : Evaluate and Process Notification .............................................................. 31 Level 3 Metrics ................................................................................................................ 39
Level 3: 305.02.02. Plan Work ...........................................................................................................40 Activities .............................................................................................................................................45
Component : Update Work Order Resource Requirements ............................................. 45 Level 3 Metrics ................................................................................................................ 56
Level 3: 305.02.04. Execute Work .....................................................................................................57 Activities .............................................................................................................................................58
Component : Prepare for Work Execution ....................................................................... 59 Component : Work Execution .......................................................................................... 63 Component : Control Work Execution.............................................................................. 64 Level 3 Metrics ................................................................................................................ 69
Level 3: 305.02.06. Close Out Work ..................................................................................................71 Activities .............................................................................................................................................72
Component : Review and Process Completed Work ....................................................... 73 Level 3 Metrics ................................................................................................................ 84 Level 2: 305.03. Shutdown Management ............................................................................. 86
Level 3: 305.03.05. Authorise Scope Amendment .............................................................................88
Component : Initiate Scope Amendment ......................................................................... 88 Level 3 Metrics ................................................................................................................ 90

Level 3: 305.03.07. Execute and Control Shutdown ..........................................................................91
Component : Prepare for Shutdown Execution ................................................................ 91 Level 3 Metrics ................................................................................................................ 95 Level 2: 305.05. Data Management ..................................................................................... 96
Level 3: 305.05.01. Maintain Plans and Measurement Documents ..................................................97 Activities ...........................................................................................................................................100
Component : Create Measurement Readings................................................................ 100 Level 3 Metrics .............................................................................................................. 105
Level 3: 305.05.03. Maintain Data Quality .......................................................................................106 Activities ...........................................................................................................................................108
Component : Rectify Time Confirmations ...................................................................... 108 Level 3 Metrics .............................................................................................................. 110 Level 1: 303. Inventory Management...................................................................................... 111 Level 2: 303.01. Warehouse and Stock Management ........................................................ 113
Level 3: 303.01.04. Process Goods Issue .......................................................................................117
Component : Process Goods Issue ............................................................................... 118 Level 2: 303.02. Inventory Planning ................................................................................... 119
Level 3: 303.02.03. Process Reservation ........................................................................................121
Component : Search, Create, Change and Review Reservations .................................. 121 Level 3 Metrics .............................................................................................................. 124 Level 1: 405. Master Data Management ................................................................................. 125 Level 2: 405.01. Manage Work Management Master Data................................................. 127
Level 3: 405.01.01. Request and Approve Work Management Master Data ..................................129 Activities ...........................................................................................................................................134
Component : Originate Master Data Request ................................................................ 134 Level 2: 405.07. Master Data Process and Quality Management ....................................... 141
Level 3: 405.07.01. Monitor and Track Master Data Request .........................................................143
Component : Analyse Master Data Request Status ....................................................... 143
1SAP 1SAP User Manual Report
How to Use This Manual

This User Manual is designed to enable the sustained and disciplined application of 1SAP processes. This User Manual can be used to support 1SAP classroom-based or self-paced training activities, and to provide Performance Support on the job. This User Manual describes all the roles and processes for a specific Key Position Type.
What the User Manual Contains:

Inventory of the Mandatory, Required or Elected Training Assessments relevant for this Key Position Type, together with an index of the processes that relate to each assessment Description of the Level 1, 2 and 3 Processes Description of the Level 4 Process Steps defining what is to be done, together with the procedure for how the step is to be done Portal Navigation Path for system-based process steps Links to system-based activities Process Metrics and descriptions Business Warehouse Reports and descriptions Glossary of Key Terms
Types of Assessments
The types of Training Assessments covered in the User Manual are: Mandatory: covers those processes that represent a material risk to BHP Billiton if not performed appropriately Required: covers those processes that are executed as standard by all positions which hold that Key Position Type Elected: covers those processes that are specific to only certain positions or Customer Segment Groups
BHP Billiton Commercial in Confidence Date Generated: 28/49/2012
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Assessments covered in this manual

The following Assessments are covered in this manual: Level 3 Processes 305.02.04. Execute Work 305.03.07. Execute and Control Shutdown 305.02.04. Execute Work 305.02.06. Close Out Work 305.05.01. Maintain Plans and Measurement Documents 305.05.03. Maintain Data Quality 305.02.01. Report Events and Work Requirements 305.03.05. Authorise Scope Amendment 305.01.01. Develop Work Strategies 305.02.02. Plan Work 305.02.04. Execute Work 405.01.01. Request and Approve Work Management Master Data 405.07.01. Track Master Data Requests 303.02.03. Process Reservation 303.01.04. Process Goods Issue Assesments Work Executor Post Work Data Recorder Training Requirement Required Required
Notification Creator
Required
Work Strategy Developer Elected Work Order Resource Organiser Elected Work Management Data Originator Reservation Creator Goods Recipient Elected
Elected Elected
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Level 1: 305. Work Management

Level 1 Process Area Description
The Work Management process provides the organisation with the ability to plan and manage work executed on the companys assets. This includes the development of strategies through to the management of work execution, analysing performance and maintaining the integrity of the system.
Level 2 Main Processes
BHP Billiton
305. Work Management
Owner: Andrew Buswell Engineer: Tugrul Bay sal Ty pe: Value-added chain diagram
305. Work Management

305.01. Work Strategy Management 305.02. Schedule Management 305.03. Shutdown Management
305.04. Contractor Management
305.05. Data Management
305.06. Work Management Monitoring and Controlling
Figure 1: Level 2 Processes
Level 1 Process Area Concepts

Key Concepts related to Work Management process are outlined in this section. Concept Description
Why is the Work The Work Management processes enable Operations with the requisite discipline Management Process for effective planning, scheduling and execution of Maintenance, Production and Important to BHP Billiton? Health, Safety, Environment and Community (HSEC) work activities in accordance with the 1SAP Work Management GLD. All activities qualifying as being Work Management relevant, no matter how insignificant, must be executed on a Work Order to ensure that all Work Management activities are managed in a safe, controlled, consistent and transparent manner. HSEC Utilisation of Work The use of the Work Management process to manage and control work Management associated with HSEC provides a simplified and integrated platform from which excellence in HSEC performance can be realistically established and maintained. Ultimately the full deployment and utilisation of the Work Management process will deliver improved control effectiveness relevant to HSEC and operational risk issues. Maintenance Utilisation of The use of the Work Management process to manage and control work Work Management associated with Maintenance activities provides a simplified and integrated platform from which excellence in Maintenance performance can be realistically established and maintained. Ultimately the full deployment and utilisation of the Work Management process will deliver improved control effectiveness relevant to
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Maintenance activities. Production Utilisation of Work Management The use of the Work Management process to manage and control work associated with relevant Production activities provides a simplified and integrated platform from which excellence in relevant Production performance can be realistically established and maintained. Ultimately the full deployment and utilisation of the Work Management process will deliver improved control effectiveness with regard to relevant Production activities. The Work Management Process clearly defines accountability to drive the discipline of Adherence to Schedule. Focus is maintained on 'planning the work and working the plan' by: - Planning what we do. - Doing what we planned. - Doing it well and delivering when we said we would, in a safe and effective manner. - Measuring, analysing, reviewing and continuously improving.
Work Management - Did You Know?
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Level 2: 305.01. Work Strategy Management

Level 2 Main Process Description
Encapsulates the creation of Work Strategies, executing investigations and managing engineering change, all of which aim to achieve loss elimination through optimal management of physical assets and the prevention of Event occurrence. The foundation of improvement opportunities are established through process discipline and rigorous history capture in 1SAP. To achieve sustainability the outcome of Work Strategy activities will normally result in a Master Data Request. Work Strategies shall be established to plan the activities required to provide the expected outcome.
Level 3 Processes
Level 2 Main Process Concepts

Key Concepts related to Work Strategy Management process are outlined in this section. Concept Overview: Develop Work Strategies Description Defines the scope and approach, selects the appropriate strategy, and defines the tasks and frequencies within the strategy. Work Strategy development may be triggered from a capital project or from analysis of feedback within other processes. Embeds the developed or modified Work Strategy by translating the defined tasks and frequencies into Master Data Requests and controlled documents. Prior to approval of the Master Data Request, the practicality of the activities are confirmed. The intent of this process step is to plan Work Strategies enabling a zero-based Work Management budget to be produced aligning with the Corporate Alignment Planning (CAP) Group Level Document. The outcome will be a 2 Year Budget as outlined by Financial Budgeting Group Level Document. This enables the identification of Contributing Factors and Root Causes for Events, including the definition of Corrective and Preventive actions to prevent Event recurrence. The Engineering Change process is initiated when a potential solution is identified that is associated with a 1SAP Technical Object at Maintainable Unit or lower and is likely to require a change to Work Management Master Data.
Overview: Deploy Work Strategies
Overview: Plan Work Strategies
Overview: Execute Investigation Overview: Manage Engineering Change
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Level 3: 305.01.01. Develop Work Strategies

Level 3 Process Description
Defines the scope and approach, selects the appropriate strategy, and defines the tasks and frequencies within the strategy. Work Strategy development may be triggered from a capital project or from analysis of feedback within other processes.
Process Components
Figure 1: Process Components Component Initiate Work Strategies Description The purpose of this component is to explain the initiation requirements of Work Strategies, to define Strategy Scopes and to gather all information required to conduct Strategy development and finalise tasks. The purpose of this component is to explain the development of Work Strategies, as well as to define, identify and assess Work Strategies and Work activities.
Define Work Strategies
Level 3 Process Concepts

Key Concepts related to Develop Work Strategies process are outlined in this section. Concept Description
Why is the Develop Work This process can be triggered by different scenarios, such as: Strategies Process - equipment related problems are identified Important to BHP Billiton? - problems in the execution of an existing Work Strategy - significant changes in the operational context or in the operating philosophy of the plant or fleet - development of a Greenfield project or an expansion of a Brownfield project - the result of an Event investigation. The Work Strategy is developed through preparation and planning, scope definition, selecting the appropriate approach, and gathering relevant information to analyse and define the Work Strategy. Where required a workshop then further defines the Work Strategy and identifies the specific work tasks that will constitute the developed Work Strategy.The process ends with the validation of proposed Work Strategy by peer review and finalising the list of work tasks. After Work Strategies have been developed, it is deployed in 1SAP through the Deploy Work Strategies process.
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Define Work Strategy
Work Strategy Management is a risk based approach to deliver the intent of work covered by the Work Management processes. When selecting a Work Strategy, the effect of the Work Strategy on the Residual Risk Rating (RRR) must be considered. The development of Work Strategies takes into account the desired business benefit and the desired result of the execution of the Work Strategy. The 1SAP Process allows for the creation of Work Strategies that are aligned to the following:- Condition Based Notification created automatically from 1SAP, for scoping, when tolerance broken - Counter Based Work Order created automatically from 1SAP, for Planning and Scheduling, when parameters met - Time Based Work Order created automatically from 1SAP, for Planning and Scheduling, when time elapsed - Failure When inspection based strategies result in no reduction in failures. A Work Plan is an SAP Master Data object used to manage scheduling of work defined in a Maintenance Item. Work Plans trigger regular creation of Work Orders via Deadline Monitoring.
Categories of Work Strategies
Work Plan
Overview: Work The intent of the 1SAP Work Management Master Data design is to simplify the Management Master Data Technical Object Structure (TOS) through a process of object consolidation based upon core functions. The structure allows for: collection of work history, grouped to allow effective analysis costcollection for budgeting provision of Work Management specific functionality such as Counters and Documents. All Maintainable Items must be linked to a Reference (Template) Functional Location structure. Within BHP Billiton, all objects of the same technical type must have the same structure. Reference Functional Location structures are simplified to ensure concentration of data for reporting and analysis. Work Management Master Data: Technical Object Structure The Technical Object Structure and associated Master Data are: simple, minimised and logical easily accessible and used consistently governed by standards aligned with policy and business needs the foundation for process discipline and operational stability leveraged from standard data for standard equipment consist of standard structures and core elements designed to enable drop in strategies for quick deployment designed to enable sharing practices and comparable reporting and analysis managed to drive sustainable quality and adherence to the standards. The Technical Object Structure is Functional Location centric. The following rules, based on business requirements, are applied to establish which equipment will be Technical Objects and Structural Elements. Within the 1SAP design, Technical Objects are: Functional Locations - Objects that do not qualify as Technical Objects are identified as lists in Document Information Records, Plant tags or Linear Objects. Safety Critical Elements. The Technical Object Structure is linked to the Construction Type of the object. The same type of Functional Location is used for the same type of equipment across BHP Billiton. This form of standardisation allows leverage of all objects that are linked to these common Construction Types. For example, a Task List linked to common equipment will only be modified at the source and this will be applied to all Functional Locations that use that Task List. This reduces time in
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developing Work Strategies for common equipment. By leveraging a common reporting system, benchmarking of performance of common equipment is enabled. Technical Objects identified as Functional Locations will be divided into: Enterprise Functional Locations Operational Functional Locations - Maintainable Units - Maintainable Items. Safety Critical Elements Safety Critical Elements are created for a Critical Control related to an HSEC Material Risk Issue or for a Critical Control (which has a recertification requirement) for a Legal Material Risk. A Safety Critical Element is installed against a Functional Location and is visible in the Technical Object Structure. A Safety Critical Element is not a piece of equipment that moves in, out and within the Technical Object Structure; rather it is a location into which equipment is installed or a non-equipment Critical Control, which requires special consideration. The Safety Critical Element created in 1SAP will, where required, contain the Recertification Date and Recertification Work Plan. These are known as serialised materials. To enable the visibility of the repair or certification of specific Materials used on equipment based Safety Critical Elements, Materials are flagged for Quality Inspection. This triggers a process within Work Management after repair or certification, to inspect and attach provided documentation to a Document Information Record. The Material Number and Manufacturers Serial Number will be included in the Document Information Record Characteristic values. Construction Assemblies Construction Assemblies are non-Plant specific objects which represent similar pieces of plant or equipment with the same Construction and Work Strategy. Notifications and Work Orders are not created with reference to a Construction Assembly. All equipment that is essentially of the same construction, although some of the components within are different, will be assigned the same Construction Type. Sub Assemblies/ Bill of Materials (BOMs) will be used to assess the differences; this will preserve the Construction Type integrity. Sub-Assemblies are logical groups of Bill of Materials, created as manageable segments to facilitate ease in locating Materials from within a Work Order. Sub-Assemblies either contain further Sub-Assemblies or Materials. Sub-Assemblies do not contain mixed items (Sub-Assemblies and Materials). Notifications and Work Orders are not created with reference to a Sub-Assembly. Certain Plant Spares require activities to be performed to maintain their integrity while in storage. These activities will ensure that they are fit for purpose when issued to a Work Order. The preservation of Plant Spares which are warehoused require the creation of a Work Plan at the Warehouse Functional Location. Preservation activities are to be grouped logically as to type of Plant Spare and the activity to be performed. A Maintenance Item is created for each group of Plant Spares, with the associated Material numbers listed in the Object List. On Work Order Planning, the Planner Controller will review inventory levels for each Material in the Object List for their Plant and adjust the default Work and Duration for the created Work Order Operations accordingly; this is required to reflect the true required effort required to perform the preservation maintenance. No consideration will be given to the time the Plant Spare has been stored; all Materials listed in the Work Order, which are stocked at that point in time, will be
Sub-Assemblies
Preservation Maintenance
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maintained in the same manner as per the Work Order Operations.
Activities
Activity Develop Work Strategies Description The objective of this activity is for the learner to: - gather the required information to conduct the Work Strategy development workshop - review Reference Functional Locations to draw off the global inventory of Work Strategies - identify required spares/parts from the Bill Of Materials to complete the details of the work activities.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31470?mode=EU
Component : Define Work Strategies 305.01.01.060. Define Work Strategy

Step What Detail The goal of this process step is to identify the specific work tasks to support the strategy. The objective is to understand in what way each failure matters, what can be done to prevent each failure, and what should be done if a suitable preventive task cannot be found. To define the Work Strategy, review the process section, equipment, and sub-assemblies while considering the following: if the equipment under analysis is part of the critical path of production how the operating strategy may restrict the Work Strategy if it has redundancy built in if they have stand-by equipment. Consider an example of how the Work Strategy may be restricted: A grinding line in a large concentrator plant runs on a Fixed Interval strategy with the shutdown windows dictated by the life of the mill liners. The entire grinding line stops only for 3.5 days every 12 weeks. The maintenance of all the equipment in the grinding line follows the same sequence. When deciding on the strategy to maintain the clutch of the mill, the options are restricted by the overall strategy of the grinding line. Next, perform the following steps: 1. Define the system to be analysed: This includes a clear definition of the boundaries of the system. This can be a piece of equipment or a sub-assembly within the equipment. 2. Define the functional requirement of the system: This is the definition of what the system is supposed to do and must be described in specific terms, quantifying each functional requirement whenever possible. The functions are sorted into two groups of Important functions and Non-important functions with appropriate justifications. The criteria to determine whether a function is important are local Operation level decisions based on specific operating conditions.
How
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3. Perform a FMECA (Failure Mode, Effects and Criticality Analysis) for important functions: For each important function, identify the failure modes and every component associated with the functional failure. Next, list only the most significant failure modes for each component, along with the most dominant plant effects for the failure mode. From this analysis, determine the criticality of the components. If a component is determined as critical, then identify appropriate causes for the potential failure modes. 4. Identify Work Strategy for critical component: From the appropriate causes determined for the failure modes, identify applicable and effective maintenance tasks to address those failure modes. In most cases this is done based on the experience of the Technicians conducting the analysis. 5. Identify Work Strategy for non-critical component: If a component is determined as non-critical, then evaluate if Run to Failure (RTF) is an option or identify a suitable Work task to maintain the equipment. In most cases, this is done based on the use of standard templates or on the experience of attendees of the analysis. Next, for each of the individual equipment or sub-assemblies for which the Work Strategy is to be developed, decide on a strategy. Work Strategies that may be applied include: Operate to Failure /Run to Failure (OTF/RTF). This strategy is applied if the consequence of the failure is insignificant or cost of prevention is higher than the cost of failure and there are no safety consequences Condition Based Maintenance (CBM). This strategy is applied where detection of the onset of failure is possible through condition monitoring or routine inspection and an interval between potential failure and actual failure (P-F interval) exists that enables intervention Fixed Time, or Interval, Maintenance (FTM). This strategy is applied to wear type failure modes to ensure that work is carried out by elapsed time or the completion of an interval Failure Finding Tasks (FFT). This strategy is applied to have checks for a hidden function at regular intervals to find out if it has failed Design Out. This strategy is applied when the consequence of failure cannot be accepted and no strategy can be applied, and an Engineering Change Request is required. The RCM (Reliability Centered Maintenance) Decision Diagram supports this process step.
305.01.01.070. Identify Specific Work Activities

Step What Detail The goal of this process step is to provide details and estimates for the identified tasks so that a cost-benefit analysis can be completed. This information also assists in completion of Work Plans, Task Lists, and other supporting Master Data objects during deployment activities. To consolidate tasks identified as part of the Work Strategy development and their associated frequencies, populate requirements onto a Work Strategy Worksheet. The frequency of Conditions Based Monitoring , Fixed Time Maintenance, or Failure Finding Tasks is characterised by: for Conditions Based Monitoring, the time available between when a potential failure can be identified and when equipment failure will result in a breakdown. Use of condition or performance monitoring techniques increases the window available for detection.
How
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for Fixed Time Maintenance, the wear characteristics or failure history of equipment components for Failure Finding Tasks, the risk associated with failure and redundancy in the system. To estimate the cost of the activities, determine labour hours (work) and associated hourly activity rate. In addition, estimate the cost of services for the task, including any associated proportion of overhead costs, for example, mobilisation and accommodation. Associated documents to assist in the execution of the activity, for example, work instructions, are also to be identified and noted. Manual Form Work Strategy Worksheet is used by this process step.
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Level 3 Metrics Process Metrics

Name Compliance to Work Plan Description Compares the number of finished system generated Work Orders in the period within tolerance, to the number of finished system generated Work Orders in the same period.
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Level 2: 305.02. Schedule Management

Enables Events to be reported and work requirements to be approved, planned, scheduled, executed and closed out. In addition, capturing appropriate history and providing feedback identifies process discipline and improvement opportunities. Interdependencies with Inventory, Procurement, Human Resources and Contractor Management enable resources to be available as planned. Similarly, interdependencies with Production enable access to plant and equipment.
Level 3 Processes

Key Concepts related to Schedule Management process are outlined in this section. Concept Description
Why is the Schedule Management Process The Schedule Management main process is important because it provides a Important to BHP Billiton? disciplined approach to managing work. The 1SAP design drives front-end loading, control and predictability. The Schedule Management Process promotes the behaviour and process discipline necessary to achieve these and is therefore the process all Operations must strive to follow and rely on to manage most work; the use of the Shutdown process is always by exception. Available resources are utilised efficiently and effectively to execute work activities, therefore contributing to reliable and safe production. The main process also contributes to effective work control by executing well defined Work Strategies and supporting continuous improvement. Overview: Report Events and Work Requirements Gathering information prior to Notification creation enables the following to occur on a Notification: - Confirmation that the Notification is valid - Initiation of an impact assessment for all Events - Initiation of Schedule Management process activities. Work planning is undertaken for Approved Planning Notifications or system generated Work Orders. All system generated Work Orders are reviewed for completeness. Once fully planned, the Work Order is Released, triggering Inventory, Procurement and scheduling.
Overview: Plan Work
Overview: Schedule Work Work scheduling assigns planned Work Order Operations to a person on the required day of execution. Prior to schedule commitment, material and service
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availability is confirmed. Work is assigned by Priority and balanced against Work Center labour capacity. The schedule is committed to by the relevant stakeholders at the Weekly Scheduling Meeting. Once confirmed, Work Packs (Work Order Form and attachments) and the Work Schedule are printed in preparation for execution. Overview: Execute Work Work execution includes all preparation, activity execution and post-activities (quality and safety checks before handover). Ensures daily Time Confirmations are completed, handover to the next shift is conducted for ongoing work and return of goods to Store. Rescheduling for urgent work and work not executed due to resource issues are managed. Alternative resource and work scope options are considered to balance the business impact. Risks associated with schedule alterations are controlled and the outcome is communicated. Close out takes the Work Order and Notification through to completion; this includes closing redundant Work Orders. This is achieved by entering failure history, initiating Subsequent Notifications and the creation of Measurement Documents. Feedback provided during work planning and execution or improvements identified during Work Management metrics analysis provide triggers for amendments to Documents, Master Data requests for creation or change, challenging of Work Strategies or amendments to terms of service provision. The default process followed is the Schedule Management Process to implement process discipline ensuring operational strength that will lead to improved reliability. The management of work through the Shutdown Management Process is the exception to this rule, when the criteria for such is met. An Outage will be considered as a Shutdown, when the budget for the activities is a minimum of US$500,000 and when a combination of the following conditions exist: production stoppage is scheduled/forecast ahead of time the total stoppage time is a significant contributor to the Production Plan a separate monetary budget exists for the Outage the budgeted / planned cost is a significant portion of the department budget permanent or temporary dedicated roles exist within the organisation for the Outage additional resources are required, e.g. labour, infrastructure, cranes is required to be managed outside of the Schedule Management & Project Management processes due to: - a requirement for scheduling and management of high volume and complex mobilisation and de-mobilisation tasks - a requirement for single point real-time management/communication of variations on multiple integrated tasks - a requirement for the identification of deviation from critical path and the need to initiate mitigation strategies to meet milestones. The criterion that an event must at least be $500,000 in value to be classed as a Shutdown is not to be used as the sole criteria for the management of work using the Shutdown Management Process. Work that exceeds the $500,000 limit must still and always be executed using the Schedule Management Process, unless the additional criterion is also met. Shutdown Cost Management Non-Work Order cost management: <$500k per annum, Purchase Requisitions Account Assignment to department overhead Cost Center >$500k per annum, able to create a dedicated Shutdown overhead Cost Center and used as the Account Assignment on Purchase Requisitions.
Overview: Reschedule Work
Overview: Close Out Work
Overview: Analyse Feedback
Shutdown Management: Objective
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Direct (Work Order) costs will settle to the Equipment Cost Center and be collected against a Statistical WBS (Work Breakdown Structure) for Shutdown cost control. Master Data Considerations - Revisions are MDO (Master Data Object) Controlled: Type 01 One Holding Revision per Planning Plant Type 02 Shutdown Event. Overview: Notifications A Notification is required for the following reasons: to report all Events (Events are defined as any occurrence that has resulted in, or has the potential to result in, adverse consequences to people, the environment, community, property, reputation or a combination of these. This definition includes equipment failures therefore the majority of Notifications will be Events). to initiate all work within the Work Management Process to initiate an Investigation to initiate an Engineering Change Assessment. All Events require Impact Assessment (Work Requests do not), therefore Notification codes of Event and Work Request are separated to support Work Performance Management processes. All Notifications will be evaluated and system approved by a holder of the Work Managing Global Job Group prior to resultant activities including (but not limited to) Investigation Notification creation, Subsequent Work Request Notification creation, Work Order creation. Notifications: Scoping The Notification Scope is to include a description of the boundaries of the work requirements. This will define the limits of the activity and any task or area specific information to assist in the planning of the resultant Work Order. During planning, each of the individual scopes of the resultant Work Orders will be utilised to build concurrent, consecutive and integrated activities, ensuring an executable schedule is formulated. The planning of the Work Orders may require in-field checks to ensure that dependant activities are verified and interactions are identified for resource optimisation. System-generated Work Orders for daily area inspections may include an allowance of time for scoping Notifications that do not have sufficient information within. Notifications: Subsequent Subsequent Notifications are to be used when there is a requirement to Notifications system-link Notifications, including: linking of Event Notifications to Investigation Notifications (Events will only be investigated when the business defined Investigation Criteria is met) linking of Investigation Notifications to Work Request Notifications (Each corrective and preventive action from an investigation requires a Work Request Notification to initiate the work) linking of Notification on PM02 Inspection Work Orders to Work Request Notifications (Work identified within the scope of the Inspection requires a new Work Request Notification to initiate the work) linking of Event or Work Request Notifications to additional Work Request Notifications (Where the resulting single Work Order from the initial Notification would contravene the Work Order granularity rules). Notifications: Outcomes Notifications as a result of processing may be either of the following: Notification Cancelled (User Status NEW, System Status NOCO) - Assigned to Notifications that are duplicates or are not appropriate for reporting in 1SAP. Notification Completed (User Status APR, System Status NOCO) -
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Assigned to Approved Notifications that do not require a Work Order (e.g. Event that does not require an Investigation, Notification that breached granularity rules and Subsequent Notifications were created to define all work requirements) Notification with Order Assigned (User Status APR, System Status ORAS & NOPR) - Approved Notifications with a Work Order. Work Orders All activities qualifying as being Work Management relevant, no matter how insignificant, must be executed on a Work Order primarily to ensure that all Work Management activities are managed in a safe, controlled, consistent and transparent manner. The execution of work extends to all functions and related personnel using the Work Management process. Although an employees Position Description outlines the responsibilities that they are to complete as part of their employment, where those responsibilities are covered by the Work Management usage of Work Orders, then Work Orders are used for the execution of those activities. Many persons will be using the same process for different execution reasons; in a similar way that many personnel use the Supply process to procure goods for different reasons. Work Order Granularity With the exception of system-generated circuit maintenance (an activity executed across multiple Maintainable Units or Maintainable Items), separate Work Orders must be raised for activities to be completed which are individually identified within the Technical Object Structure. One work-front may generate different information sets that need to be readily and separately identifiable in 1SAP. These differences may include: Materials Costs History Work Order Type Technical Object Main Work Center. Work Orders are required to be neither created for individual tasks in a sequence dependant activity nor is a Work Order to be created for extended activities although on a single Technical Object. The required Work Order granularity can be determined by assessing whether the proposed Work Order Composition: has a predefined start and finish date is a defined package of work contains work that is required to be entirely completed to finish a task (i.e. A Work Order Operation could not remain open and the work be deemed a success or the equipment returned to service) can be scheduled at the same time, although being scheduled over a number for Schedule Periods can be assigned a Main Work Center solely accountable for the execution of all tasks within. Notifications are only approved for Work Order creation where the resultant Work Order complies with the granularity rules.
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Level 3: 305.02.01. Report Events and Work Requirements

Any Event occurrence which is represented as an Impact Type on the BHP Billiton Severity Table is reported and work requirements are identified and assessed based on Priority. Notifications are approved for further processing and Immediate Work Orders are created for Approved Immediate Notifications.
Process Components
Figure 1: Process Components Component Description
Event Notification Identification The purpose of this component is to explain the activities required when an Event has been identified which requires reporting. These activities include determination of emergency response activities, notifying stakeholders, legal professional privilege requirements and information gathering. Create Scoped Notification The purpose of this component is to explain the activities required when creating a scoped Notification. These activities include identifying the Technical Object, populating the Notification with the required detail and reviewing the status of created Notifications. The purpose of this component is to explain the activities required when reviewing a Notification to determine validity. These activities include a detailed review of the Notification, approving valid Notifications, cancelling redundant Notifications and informing stakeholders. The purpose of this component is to explain how to identify the requirement for Subsequent Notifications. These activities include identifying specific Notification requirements, whether an Investigation Notification is required, and the actual creation of the Subsequent Notification. The purpose of this component is to explain the activities required when creating an immediate Work Order. These activities include creating a PM03 Work Order from an Immediate Priority Notification then releasing and printing the Work Order.
Evaluate and Process Notification
Process Subsequent Notification
Create Immediate Work
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Key Concepts related to Report Events and Work Requirements process are outlined in this section. Concept Initiate Escalation Protocol Description When consulting the Escalation Protocol for the Operation, determine the organisational positions to be notified/consulted with regards to this specific Event. The position to contact may vary depending on the Event Impact type, Actual and Potential Risk. To identify a Technical Object on which to create a Notification, the primary method is to identify the location within the Technical Object Structure. Where this is not easily achieved due to the user not understanding the Plant structure or the business utilising a Plant Tagging System such as the use of Plant Tags or Process and Instrumentation Diagrams (P&IDs), a search for the specific Technical Object is undertaken by first searching by Safety Critical Element, then if the location is not found continue to search by Functional Location. Due to an Event being an 'occurrence', simply stated 'something happened' that resulted in or could have resulted in adverse consequences, the majority of Notifications created within the business will be coded as 'Events'. Notifications coded as 'Work Request' would be rare due to these Notifications not being as a result of an 'occurrence'. On creation of a Notification the user is required to fully complete the Event/Work Details tab of the Notification in preparation for future evaluation. Additional information on other tabs is only included if known. Additional information to complete Notification approval and evaluation process is entered into the Notification, including Impact Data for Events. Where additional information is required to complete this Evaluation, the most appropriate person from whom this information may be obtained, is determined.
Identify Technical Object
Report Events
Populate Notification
Evaluate Notifications
Why is the Report Events It enables the reporting of Events, and the initiation of Work, Investigations and & Work Requirements Engineering Change Requests. This process is the trigger for schedule Process Important to BHP management activities. Billiton?
Activities
Activity Create Work Request Notification Description The objective of this activity is for the learner to: - initiate the creation of a Work Request Notification against a Functional Location by using a known Plant Tag, P&ID Identifier or Linear Object - populate the Work Request Notification with details of the Work Request - update the Work Request Notification with a Document Information Record - review a created Work Request Notification to check on its status - update the Work Request Notification with User Status 'INF' (Additional Scope Required) with information obtained during the review process.
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Create Event Notification
The objective of this activity is for the learner to: - initiate the creation of an Event Notification against a Safety Critical Element by using a known Plant Tag or P&ID Identifier or through the Functional Location Structure - initiate the creation of an Event Notification against a Functional Location by using a known Plant Tag, P&ID Identifier or Linear Object, where the location cannot be easily identified through the Technical Object Structure - populate the Event Notification with details of the Event - update the Event Notification with a Document Information Record - execute the Event Notification review methodology selected earlier - update the Event Notification with User Status 'INF' (Additional Scope Required) with information obtained during the review process - generate required Event Notification information to enable the collation of the Event Report to be sent to External Stakeholders.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31843?mode=EU Create Maintenance Engineering Change Notification The objective of this activity is for the learner to: - initiate the creation of a Maintenance Engineering Change Notification against a Functional Location by using a known Plant Tag, P&ID Identifier or Linear Object - populate the Maintenance Engineering Change Notification with details of the Maintenance Engineering Change - update the Maintenance Engineering Change Notification with a Document Information Record - review a created Maintenance Engineering Change Notification to check on its status - update the Maintenance Engineering Change Notification with User Status 'INF' (Additional Scope Required) with information obtained during the review process.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31851?mode=EU Create Investigation Notification The objective of this activity is for the learner to: - initiate the creation of an Investigation Notification against a Functional Location by using a known Plant Tag, P&ID Identifier or Linear Object - populate the Investigation Notification with details of the Investigation - update the Investigation Notification with a Document Information Record (DIR) - review a created Investigation Notification to check on its status - update the Investigation Notification with User Status 'INF' (Additional Scope Required) with information obtained during the review process.
Component : Event Notification Identification
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305.02.01.010. Determine Emergency Response Activities

Step What Detail The goal of this process step is to determine if any Emergency Response activity is required to control the Event and ensure there is no further impact on People, the Environment or Property. These activities are carried out without the use of a Work Order and are governed by the Operation's Emergency Response protocols. To determine appropriate Emergency Response activities, without a Work Order, consider the potential HSEC impacts should the Event not be controlled or mitigation steps taken to limit any immediate knock-on effects from the Event. Where Emergency Response activities are deemed to be required, or where doubt exists as to whether they are required, initiate the Operations Emergency Response protocols.
How
305.02.01.020. Execute Emergency Response Activities

Step What Detail The goal of this process step is to execute Emergency Response activities, without a Work Order, to control the Event to ensure there is no further impact on People, the Environment or Property. To execute Emergency Response activities, without a Work Order, take action as per the Operations Emergency Response protocols and as directed by Emergency Response team members.
How
305.02.01.030. Notify Internal Stakeholders

Step What Detail The goal of this process step is to perform the following: Initiate the Escalation Protocol to notify internal stakeholders of Event occurrence, where required Initiate the Escalation Protocol to notify internal stakeholders of the requirement for Schedule Interrupt Work, where required Initiate the Escalation Protocol to assess the necessity of performing Immediate or Urgent Work, where required Obtain confirmation from stakeholders of Event / Work Request validity and subsequent authorisation to conduct Initial Information Gathering.
How
To notify internal stakeholders of Events, and where required Schedule Interrupt Work, perform the following: Refer to the Escalation Protocol for guidance on which stakeholders require notification and timeframes for providing this notification Obtain confirmation that Event / Work Request is valid for valid Event / Work Requests Obtain authorisation to conduct Initial Information Gathering.
305.02.01.060. Conduct Initial Information Gathering
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Step What
Detail The goal of this process step is to gather initial information on the Event / Work Request to enable all of the following to occur: Confirm the Event / Work Request is valid, for valid Work Requests confirm any impact on the published schedule Confirm that the necessary information on the Schedule Interrupt Work Request is obtained as soon as possible.
How
To gather initial information perform all of the following activities: Collect information on all of the following: - Main Work Center accountable for evaluating the Event / Work Request To gather initial information perform all of the following activities: Collect information on all of the following: - Main Work Center accountable for evaluating the Event / Work Request - supporting documentation associated with the Event / Work Request that can assist in planning activities (e.g. reports, diagrams, photos). - specific Functional Location - exact Date and Time of Event occurrence, or Work Request identification, or Audit completion - any relevant Task List which may exist - required Start and End dates and times - where a requirement for an activity is determined which does not have a Task List (e.g. one-off or new task), identify the following for each task, where known: - Estimated Work Effort Duration (in hours) - Name of person to perform the task, where required; before nominating the person responsible for the task, the following must be performed: - Discuss the task with the individual and obtain commitment to Start / Finish dates and estimated Work Effort Duration (in hours) - where required, obtain approval from their line manager for task assignment to the individual. for Events where it is clear an Investigation will be required, perform initial information gathering in accordance with the Investigation Protocol. when an Immediate or Urgent work requirement is identified, perform all of the following: - identify any pre-planned future work that can be executed to rectify the fault instead of creating a new Work Request or work that should also be completed at the same time as the interrupt work. This may also include future work on any associated equipment. The following points are relevant for future pre-planned Work: - Inform relevant people that the pre-planned work should be executed to ensure that the jobs are done safely - Arrange for the execution of the opportune work, if approved (this may not be possible) - the decision to execute opportune work is based on many factors including availability of resources, duration of required work and pre-planned work. - identify all job related HSEC requirements (including Legislative and Fatal Risk Controls) prior to and during work execution. - when determining which Notification Priority to set on the Event/Work Request, consideration is to be given to balance the HSEC, Legal and Financial Risk, including Work Order resource planning requirements. Once initial information gathering activities have been performed, where required review with stakeholders to confirm the following: the Event / Work Request is valid. To confirm if the Event and Work Request is valid, business judgement is to be used. If determined as non-valid ensure this is
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communicated to the Event / Work Request initiator. for valid Work Requests, whether it will interrupt a published Schedule the necessary information has been obtained to enable Notification creation for all valid Work Requests assess the Work Request against the granularity rules (Referenced in the Schedule Management Design Intent). If any of the granularity rules have been breached more than one Work Request Notification will be required. - supporting documentation associated with the Event / Work Request that can assist in planning activities (e.g. reports, diagrams, photos). - specific Functional Location - exact Date and Time of Event occurrence, or Work Request identification, or Audit completion - any relevant Task List which may exist - required Start and End dates and times - where a requirement for an activity is determined which does not have a Task List (e.g. one-off or new task), identify the following for each task, where known: - estimated Work Effort Duration (in hours) - name of person to perform the task, where required; before nominating the person responsible for the task, the following must be performed: - discuss the task with the individual and obtain commitment to Start / Finish dates and estimated Work Effort Duration (in hours) - where required, obtain approval from their line manager for task assignment to the individual. for Events where it is clear an Investigation will be required, perform initial information gathering in accordance with the Investigation Protocol. when an Immediate or Urgent work requirement is identified, perform all of the following: - identify any pre-planned future work that can be executed to rectify the fault instead of creating a new Work Request or work that should also be completed at the same time as the interrupt work. This may also include future work on any associated equipment. The following points are relevant for future pre-planned Work: - Inform relevant people that the pre-planned work should be executed to ensure that the jobs are done safely - Arrange for the execution of the opportune work, if approved (this may not be possible) - the decision to execute opportune work is based on many factors including availability of resources, duration of required work and pre-planned work. - identify all job related HSEC requirements (including Legislative and Fatal Risk Controls) prior to and during work execution. - when determining which Notification Priority to set on the Event/Work Request, consideration is to be given to balance the HSEC, Legal and Financial Risk, including Work Order resource planning requirements. Once initial information gathering activities have been performed, where required review with stakeholders to confirm the following: the Event / Work Request is valid. To confirm if the Event and Work Request is valid, business judgement is to be used. If determined as non-valid ensure this is communicated to the Event / Work Request initiator. for valid Work Requests, whether it will interrupt a published Schedule the necessary information has been obtained to enable Notification creation for all valid Work Requests assess the Work Request against the granularity rules (Referenced in the Schedule Management Design Intent). If any of the granularity rules have been breached more than one Work Request Notification will be required.
Component : Create Scoped Notification
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305.02.01.090. Identify Location in Structure List

Step What Detail The goal of this process step is to initiate the creation of a Notification by using the Technical Object Structure: Events are created at the Technical Object that best represents the physical location where the Event occurred Work Requests are created at the lowest possible level in the structure to ensure accurate identification of the object affected by the work Events which will require the execution of work are created at the lowest possible level in the structure to ensure accurate identification of the objects affected by the work Engineering Change Notifications are created at the Technical Object where the proposed change will be implemented. To record related details in 1SAP as a Notification, access to 1SAP is required. The person who identified the Event or Work requirement, determines their 1SAP access: if they do not have access, due to not having system access to 1SAP, they must contact their Supervisor, or delegated person, to request them to create a Notification and to furnish them with all the relevant details if they do have access, they will proceed to create the Notification in 1SAP. To request the Supervisor or delegated person to create Notifications, the following points need to be considered: the person requested to create the Notification has 1SAP access and is generally part of the originating department the Event Reporter or Work Requestor gives clear details of what, where and when with regard to the Event Details or work requirements the Event Reporters / Work Requestor's name and contact details are to be known, in case further details are required for clarification. The original requester details will be defined in the Notification as the contact in the 'Reported by' field and their contact details noted in the 'Long Text' of the created Notification. To locate the Technical Object use transaction Create Notification from Structure List' and perform the following: drill down through the Technical Object Structure and select the Technical Object required. When selecting the Technical Object the following must be adhered to: - a Notification for an Event / Work Request that impacted or impacts on a Safety Critical Element must always be created at the Safety Critical Element - if it is not possible to identify the required Functional Location or Safety Critical Element through the Functional Location Structure, proceed to search for a Functional Location or Safety Critical Element using the known Plant Tag, P&ID identifier or Linear Object. Where it is confirmed that a Technical Object does not exist at the granular level that you require, select the next level up within the Technical Object Structure. - Events are created at the Technical Object that best represents the physical location where the Event occurred, with the following considerations: - where an Event involves equipment, that as a result of the Event requires repair, the Notification must be created at the Technical Object that represents the equipment. - where an Event involves equipment, that as a result of the Event does not require repair, the Notification must be created at the Technical Object that best represents the physical location where the Event occurred. A description of the equipment is to be made in the Notification Long Text. - where an Event involves more than one piece of equipment, that as a result of the Event does not require repair, the Notification must be created at the Technical Object that best represents the physical location where the Event occurred. A description of all equipment is to be made in the Notification Long Text. - where an Event involves more than one piece of equipment, that as a result of the Event one piece of equipment requires repair and additional equipment does not
How
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require repair, the Notification must be created at the Technical Object that represents the equipment that requires repair and reference to the equipment that does not require repair is to be made in the Notification Long Text. - where an Event involves more than one piece of equipment, that as a result of the Event more than one piece of equipment requires repair, the Event Notification will be created at the Technical Object that represents the equipment most damaged or impacted by the Event and reference to the other equipment is to be made in the Notification Long Text. An additional new Work Request Notification will also be created for each piece of equipment that requires repair at the Technical Object that represents the piece of equipment. - where an Event occurs in an office environment that is outside the responsibility of an Operation, the Event Notification will be created at the Technical Object that best represents responsibility for that office as individual offices do not have specific Technical Objects (e.g. A Notification for an Event occurrence at an office that is outside the responsibility of an Operation, but within the responsibility of the Asset or the Customer Sector Group (CSG) will be created at the applicable Asset or Customer Sector Group (CSG) level Technical Object. Similarly, the Notification for an Event occurrence within an office that houses Marketing, Group Functions or Minerals Exploration resources will be created against the most relevant Technical Object, which typically will be the Country within which the office is located, under each of the respective business areas). - where an Event involves a worker whilst travelling outside of their base work location, the Event is to be created against the Technical Object that best represents that part of the business that is accountable for managing the risk associated with the Event (e.g. A worker travelling between Operations is involved in a vehicle accident; the Technical Object selected would be the persons base location, as they would generally be accountable for managing off-site travel risk for the person involved. Another example is when a worker from one location is involved in an Event whilst working at a secondary location that is not that workers base location, the Technical Object selected would be the secondary location as management at this location are generally accountable for risk management at this locality). - Work Requests are created at the lowest possible level in the Technical Object Structure to ensure accurate identification of the object affected by the work. - Events which require the execution of work are created at the lowest possible level in the Technical Object Structure to ensure accurate identification of the objects affected by the work. once the appropriate Technical Object has been identified, select the Technical Object and from the Menu path > Create notification > General. The Notification will be populated in the next step. Note: Where the object is to be located by its Plant Tag or its Linear Object, it will not be located within this process step. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.100. Locate Safety Critical Element by Tag

Step What Detail The goal of this process step is to initiate the creation of a Notification against a Safety Critical Element by using a known Plant Tag or P&ID Identifier, where the Safety Critical Element cannot be easily identified through the Functional Location Structure. To locate a Safety Critical Element by Plant Tag or P&ID identifier use transaction ''Create Notification from Safety Critical Element Search' and complete only the following fields:
How
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Class Type - 002 (Equipment class) Class - PM_EQUI_COMM Maintenance plant Enter the relevant Maintenance Plant Click 'Valuation' button and within the popup screen enter the Plant Tag or P&ID Identifier in the 'Plant Tag Identifier' field. Click 'Continue (Enter)' button (green tick at bottom left) Execute Transaction. If there is only one Safety Critical Element found the 'Display Equipment: General Data' screen will be displayed. In this case perform the following: navigate to Structure > Structure List, this will return 'Display Equipment: Structure List' screen to display the Functional Location Structure where the Safety Critical Element is assigned Click the 'Levels above' button. If there is more than one Safety Critical Element found, a list of results will be returned in the 'Display Equipment: Equipment List' screen. In this case perform the following: from the returned Safety Critical Element list, select the Safety Critical Element line Item, then navigate to Structure > Hierarchy List, this will return 'Display Equipment: Structure List' screen to display the Technical Object Structure where the Safety Critical Element is assigned, Click the 'Levels above' button. Select the Safety Critical Element and from the menu path Goto > Create notification > General. Should no Safety Critical Element be found, proceed to search for a Functional Location using the known Plant Tag, P&ID or by Linear Object. Note: Where the object to be located is a Linear Object, this will not be located within this process step. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.110. Locate Functional Location by Tag / Linear Object

Step What Detail The goal of this process step is to initiate the creation of a Notification against a Functional Location by using a known Plant Tag, P&ID Identifier or Linear Object, where the location cannot be easily identified through the Technical Object Structure. To locate a Functional Location by Plant Tag, P&ID identifier or Linear Object use transaction 'Create Notification from Functional Location Search' and perform one of the following within the screen: Enter only the following: - Class Type 003 - Class - PM_FLOC_COMM - Maintenance Plant - Enter the relevant Maintenance Plant - Click 'Valuation' button and within the popup screen enter the Plant Tag or P&ID Identifier in the 'Plant Tag Identifier' field, or enter the Linear Object ID in the 'Linear Object' field. - Click 'Continue' button (green tick at bottom left) Enter only the following:
How
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- Sort field - Enter the Plant Tag. Execute the transaction. If there is only one Functional Location found the 'Display Functional Location: Master Data' screen will be displayed. In this case perform the following: Navigate to Structure > Structure List, this will return Display Functional Location: Structure List' screen. If there is more than one Functional Location found, a list of results will be returned. In this case perform the following: from the returned Functional Location list, select the Functional Location line Item, then navigate to Structure > Hierarchy List this will return the Functional Location Structure. Select the Functional Location and from the Menu path Goto > Create notification > General. Where it is confirmed that the Technical Object does not exist, select the next level up within the Technical Object Structure. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.120. Check for Notification Duplicates

Step What Detail The goal of this process step is to check for Notification Duplicates. Duplicate Notifications are closed without saving. To check for Notification Duplicates continue in the current transaction and determine if any existing Notifications and Work Orders are open for the same Technical Object. Before populating the required fields within the initiated Notification, an Object Information box will appear if there are open Notifications and Work Orders for the same Technical Object, the following is relevant with regards to the Object Information box: the Object Information box can be used to identify previously identified Events and Work Requests for the same Technical Object by drilling into the listed Notifications and Work Orders Review the listed Notifications and Work Orders, if an existing Notification or Work Order is, found exit the Notification being created without saving. If no existing Notification exists continue with creating a new Notification. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
How
305.02.01.130. Update Notification with Document Information Record

Step What Detail The goal of this process step is to update the Notification with a Document Information Record (DIR). To update the Notification with the Document Information Record perform the following:
How
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Locate the Notification using transaction 'Change Notification' Enter the Notification number and execute the transaction. For Controlled Documents that have been created as a 1SAP Document Information Record select the 'Documents & Investigation Findings' Tab, scroll down to the Linked Documents sub screen and perform the following: Ty. PMA Document Enter the Document Information Record (DIR) number, if unknown perform the following: - in the Document field Click the Possible Entries Search button, the search functionality box is displayed - from the popup box select 'Find document via class' - in the 'Find Objects in Classes' screen complete the following fields: - Class - DM_PMAC_COMM (Document Info record Common) - Class Type 017 (Document management) - Click 'Continue (Enter)' button, in the search screen enter the relevant Document Information Record (DIR) Characteristic values (e.g. Maintenance Planning Plant, Main Work Center, etc) - Click 'Find in initial class' button, a list of Object (Document Number) is generated - Click 'Change Layout' button (button to the right of green tick) to bring other Characteristic value into the list if necessary (e.g. Description) - If further detail is required on the Document Information Record, highlight the line item and Click 'Display Document Info Record' button (arrow button next to Clock button) and choose 'Display document' to display the Document Information Record Master Data. To return to the list Click 'Back' button - In the 'Find Objects in Classes' screen highlight the desired line item (Object) and Click 'Copy' button, the document number is copied over to Linked Documents sub screen. Hit the Enter button to allow details to be updated. Once the Document Information Record (DIR) has been assigned to the Notification, save and exit the Notification.
305.02.01.140. Review Created Notification

Step What How Detail The goal of this process step is to review a created Notification to check on its status. To locate Notifications use transaction 'Display Notifications (Selection List) and complete only the following fields: Outstanding - Select In process - Select Completed - Select Functional location - Enter relevant Functional Location or range Reported by - Enter user ID Planning plant - Enter the planning Plant Execute the search and a list of Notifications meeting the above criteria will be displayed. The list may be sorted by Technical Object for ease of review. Select the individual Notifications and process them using the Details button. From within the Notification, any Work Order that has been created may also be reviewed. Checking the User and System Status of the Notification and Work Order, determine the progress of the Notification and Work Order through Approval, Planning, Execution and Close-Out.
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Component : Evaluate and Process Notification 305.02.01.121. Populate Event Notification

Step What Detail The goal of this process step is to populate the Notification with details of the Event. All known details of the Event are entered in as much detail as possible to assist in determining Impacts, Investigation Requirements, and Work Order requirements. Event Notifications are created where there has been an Event or Issue identified that has had an actual impact or has potential impact for an impact across the impact types of Safety, Health, Environment, Social / Cultural, Legal, Reputation or Financial. If an Event has occurred, which also requires work to be executed, an Event Notification is to be created. How To populate the Notification with details of the Event continue in the current transaction. Event Notifications with an identified Work requirement are to contain a detailed scope of work prior to Approval, thus enabling accurate Planning of the work required. Often, the required detail for Planning can only be obtained in the condition under which the task was identified (e.g. Obtaining the required part numbers from inside a motor control station while under isolation). The Event Notification (with an identified Work requirement) scope must include reference to an appropriate Task List, where available. Notifications that have an insufficient scope of work will be returned to the creator, updated by the Main Work Center owner or assigned to a Subject Matter Expert for scoping. If the Work Order granularity rules (Referenced in the Schedule Management Design Intent) would be broken due to the nature of the Work Requirement identified for the Event, more than one Notification is required. In this instance perform one of the following: Exit the Notification without saving and determine the scope of the Work requirement, then create the required number of Notifications to comply with the Work Order granularity rules. Continue with the current Notification with reduced scope of work and create a New Work Request Notification for any Work Requirements which will not be addressed in the current Event Notification. Proceed to enter information in the required fields to populate the Notification
Event / Work Details Tab: Complete the following fields: Notification Header Brief description of what occurred Coding - in the first field Click the blank field, the 'Possible Entries Search' button will appear, Click the 'Possible Entries Search' button. - from the pop-up menu select S001 Event Report then Click the 'Choose' button (green tick) - following selection, both coding fields are populated with Notification coding detail. To the right of these fields the coding text description is displayed - reported by Record the name of the person who identified and reported the Event be performing one of the following:
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- if the person who reported the Event has a 1SAP profile, but their ID is unknown, perform the following: - Click in the blank field, the 'Possible Entries Search' button will then appear, Click the 'Possible Entries Search' button. - on the pop-up menu enter the first name/last name of the person; Click the 'Start Search' button (green tick at bottom) - from the returned search list, select the person; Click the 'copy' button (green tick). The person's 1SAP ID is then populated into the 'Reported by' field. - if the person who reported the Event has a 1SAP profile and their ID is known enter the person's ID manually into the 'Reported by' field - if the person who reported the Event does not have a 1SAP profile enter their name as free text in the field (12 character limit). Use initials for Given Names and write family name in full. Functional loc. Functional Location, pre-populated from previous process step Equipment Pre-populated from previous process step where a Safety Critical Element has been identified Planner Group Pre-populated from previous process step, update to the Planner Group responsible if displayed selection is incorrect Main WorkCtr Main Work Center, pre-populated from previous process step, update to the Main Work Center Responsible if displayed selection is incorrect Notif. Date Enter the Date and Time of Event occurrence. Where date is unknown enter date on which Event was reported, where Time is unknown enter '00.00.01' Priority Select the appropriate Priority for execution of any work requirements Long Text A detailed description of the Event must be included in the Notification Long Text by performing the following: - Click the 'Information' button (to the right of scoping template text), the scoping template will then be displayed in a pop-up box: - Click 'Copy Text' to update long text with scoping template text - within the Long Text field provide the required information as requested by the scoping template, including any known hazards in performing work requirements. If additional information, to scoping template prompts, is required enter the additional information below the scoping template prompts. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.122. Populate Work Request Notification

Step What Detail The goal of this process step is to populate the Notification with details of the Work Request. All known details of the Work Request are entered in as much detail as possible to assist in determining Work Order requirements. Work Request Notifications are created when there has been no Actual impact and there is no Potential for an impact across the impact types of Safety, Health, Environment, Social / Cultural, Legal, Reputation, Legal or Financial. Work Requests for implementing an Engineering Change will have had the Prior Notification field automatically populated with the Completed Engineering Change Assessment Notification number. Where this is not the case, the Notification must be coded as Engineering Change. How To populate the Work Request Notification with details, continue in the current transaction.
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Work Request Notifications are to contain a detailed scope of work prior to Approval, thus enabling accurate Planning of the work required. Often, the required detail for Planning can only be obtained in the condition under which the task was identified (e.g. Obtaining the required part numbers from inside a motor control station while under isolation). The Work Request Notification scope must include reference to an appropriate Task List, where available. Notifications that have an insufficient scope of work will be returned to the creator, updated by the Main Work Center owner or assigned to a Subject Matter Expert for scoping. If the Work Order granularity rules (Referenced in the Schedule Management Design Intent) would be broken due to the nature of the identified Work Requirement, more than one Work Request Notification is required. In this instance perform one of the following: Exit the Notification without saving and determine the scope of the Work requirement, then create the required number of Notifications to comply with the Work Order granularity rules Continue with the current Notification with reduced scope of work and create a New Work Request Notification for any Work Requirements which will not be addressed in the current Work Request Notification. Proceed to enter information in the required fields to populate the Notification Event / Work Details Tab: Complete the following fields: Notification Header Must contain a brief description of the work requirement Coding: - in the first field Click the blank field, the 'Possible Entries Search' button then appears, Click the 'Possible Entries Search' button - from the pop-up menu select S002 Work Request and then Click the 'Choose' button (green tick) - following selection, both coding fields are populated with Notification coding detail. To the right of these fields the coding text description is displayed. reported by Perform one of the following: - if the person who reported the Work Request has a 1SAP profile, but their ID is unknown, perform the following: - Click in the blank field, the 'Possible Entries Search' button will then appear, Click the 'Possible Entries Search' button. - on the pop-up menu enter the first name/last name of the person; Click the 'Start Search' button (green tick at bottom). - from the returned search list, select the person; Click the 'copy' button (green tick). The person's 1SAP ID is then populated into the 'Reported by' field. - if the person who reported the Work Request has a 1SAP profile and their ID is known enter the person's ID manually into the 'Reported by' field - if the person who reported the Work Request does not have a 1SAP profile, enter their name as free text in the field (12 character limit). Use initials for Given Names and write family name in full. Functional loc. Functional Location, pre-populated from previous process step Equipment - Pre-populated from previous process step where a Safety Critical Element has been identified Planner Group Pre-populated from previous process step, update to the Planner Group responsible if displayed selection is incorrect Main WorkCtr Main Work Center, pre-populated from previous process step, update to the Main Work Center Responsible if displayed selection is incorrect. Notif. Date - Enter the current Date / Time of Notification creation - if creating a Work Request Notification to record outcomes from processes such as Audits and Inspections, enter the Date / Time the Audit or Inspection was completed
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Priority Select Priority based on HSEC Risks and work urgency Long Text A detailed description of the Work Request must be included in the Notification Long Text by performing the following: - Click the 'Information' button (to the right of scoping template text), the scoping template will then be displayed in a pop-up box: - Click 'Copy Text' to update long text with scoping template text - within the Long Text field provide the required information as requested by the scoping template, including any known hazards in performing work requirements. If additional information, to scoping template prompts, is required enter the additional information above the scoping template prompts - if creating a Work Request for a corrective or preventive action from an Investigation Notification, or Engineering Change Notification ensure the following is defined in the Notification Long Text: - detailed description of the task - Name of person to perform the task, if known - Start and Finish date for the task - Estimated Work Effort Duration (in hours) - any resources required to enable task completion. - all Capital Work is required to contain a WBS (Work Breakdown Structure) Element in the Notification long text. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.124. Populate Engineering Change Notification

Step What Detail The goal of this process step is to populate the Notification with details of the Engineering Change Request. All known details of the Engineering Change Request are entered in as much detail as possible to assist in determining validity of the request, and Work Order requirements. An Engineering Change Notification is created to initiate an Engineering Change Assessment when a potential solution is identified that is associated with a 1SAP Technical Object at Maintainable Unit or lower and is likely to require a change to Work Management Master Data. How To populate the Engineering Change Notification with further details continue in the current transaction. Proceed to enter information in the required fields to populate the Notification Event / Work Details Tab: Complete the following fields: Notification Header The Notification header must contain a short description detailing the nature of the change requested. Coding Select the appropriate code - in the first field Click the blank field, the 'Possible Entries Search' button then appears, Click the 'Possible Entries Search' button - from the pop-up menu select S003 Engineering Change - following selection, both coding fields are populated with Notification coding detail. To the right of these fields the coding text description is displayed. reported by Perform one of the following: - if the person who reported the Engineering Change Request has a 1SAP profile, but their ID is unknown, perform the following: - Click in the blank field, the 'Possible Entries Search' button will then appear, Click the 'Possible Entries Search' button
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- on the pop-up menu enter the first name/last name of the person; Click the 'Start Search' button (green tick at bottom) - from the returned search list, select the person; Click the 'copy' button (green tick). The person's 1SAP ID is then populated into the 'Reported by' field. - if the person who reported the Engineering Change Request has a 1SAP profile and their ID is known enter the person's ID manually into the 'Reported by' field - if the person who reported the Engineering Change Request does not have a 1SAP profile, enter their name as free text in the field (12 character limit). Use initials for Given Names and write family name in full. Priority Select Priority based on HSEC Risks and work urgency Functional loc. Functional Location, pre-populated from previous process step Equipment - Pre-populated from previous process step where a Safety Critical Element has been identified Planner Group Pre-populated from previous process step, update to the Planner Group responsible if displayed selection is incorrect Main WorkCtr Main Work Center, pre-populated from previous process step, update to the Main Work Center Responsible if displayed selection is incorrect Notif. Date - Enter the current Date / Time of Notification creation Long Text The Notification Long Text must be populated for all Engineering Change Notification by performing the following: - Click the 'Information' button (to the right of scoping template text), the scoping template will then be displayed in a pop-up box: - Click 'Copy Text' to update long text with scoping template text - within the Long Text field provide the required information as requested by the scoping template - if additional information, to scoping template prompts, is required enter the additional information above the scoping template prompts. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.125. Assign Uncontrolled Document to Notification

Step What Detail The goal of this process step is to assign an Uncontrolled Document to the Notification. Uncontrolled PDF documents which are available to support the support the Notification (e.g. photo, sketch, report),are attached to the Generic Object for Services (GOS) on the Notification using the function 'Store Business Document'.
How
To attach the uncontrolled document to the Notification perform the following: Click the 'Services for Object' arrow button Navigate to Create > Store business document, the 'Archive from FrontEnd' screen displays Double Click '1SAP: Plant Maintenance Notification' and browse the file from local drive Select the file and Click 'Open' button, then Click 'Continue' button Enter a note in the Notification Long Text regarding the relevance of the attachment Adding attachments to the Notification General Object Services, will assign the Notification User Status 'DOC'. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
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305.02.01.126. Assign Controlled Document to Notification

Step What Detail The goal of this process step is to assign a Controlled Document to the Notification as a Document Information Record. This process is performed after Notification mandatory fields have been populated. The following documentation must be attached to the Notification as a Document Information Record (Controlled Document): all documentation under Legal Professional Privilege all Reports to External Stakeholders and evidence of reporting (e.g. email in PDF form) all documentation which, according to Business requirements, must remain private and confidential (e.g. health related record that support a health related investigation). How To assign a Controlled Document that has been created as a 1SAP Document Information Record, ensure Notification mandatory fields have been populated then select the 'Documents & Investigation Findings' Tab, scroll down to the Linked Documents sub screen and perform the following: Ty. PMA Document Enter the Document Information Record (DIR) number, if unknown perform the following: - in the Document field Click the Possible Entries Search button, the search functionality box is displayed - from the popup box select 'Find document via class' - in the 'Find Objects in Classes' screen complete the following fields: - Class - DM_PMAC_COMM (Document Info record Common) - Class Type 017 (Document management) - Click 'Continue (Enter)' button, in the search screen enter the relevant Document Information Record Characteristic values (e.g. Maintenance Planning Plant, Main Work Center, etc) - Click 'Find in initial class' button, a list of Object (Document Number) is generated - Click 'Change Layout' button (button to the right of green tick) to bring other Characteristic value into the list if necessary (e.g. Description) - if further detail is required on the Document Information Record (DIR), highlight the line item and Click 'Display Document Info Record' button (arrow button next to Clock button) and choose 'Display document' to display the Document Information Record Master Data. To return to the list Click 'Back' button - in the 'Find Objects in Classes' screen highlight the desired line item (Object) and Click 'Copy' button, the document number is copied over to Linked Documents sub screen. Hit the Enter button to allow details to be updated. For Controlled Documents that have not been created as a 1SAP Document Information Record, proceed to the creation of the Document Information Record (DIR) Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.127. Assign Task List to Notification

Step What Detail The goal of this process step is to assign the required Task List to the Notification. Task Lists provide sufficient information for effective Planning. This process is performed
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after Notification mandatory fields have been populated. The following requirements apply to the assignment of a Task List to the Notification: HSEC Investigation Task List must be assigned to Investigation Notifications Task List must be assigned to Work Request Notifications, Event Notifications and Engineering Change Notifications where required. How To assign a Task List to the Notification, ensure Notification mandatory fields have been populated then perform the following: Open the Task List tab on the Notification by Clicking on the 'Search task list' button (binoculars), the 'Display Task Lists: Task List Selection' screen appears with the Functional Location Construction Type defaulting in the 'Assembly' field Execute this screen and a list of related Task Lists will appear. The appropriate Task List can then be selected Enter the Main Work Center, in the Work Center field, to narrow the search if required Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.128. Finalise Notification Population

Step What Detail The goal of this process step is to finalise the Notification Population process.
How
To finalise the Notification Population process, proceed to save the Notification. The System Status will default to 'OSNO' (Notification Outstanding) and User Status 'NEW' (New) once basic details are entered. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.01.170. Execute Notification Review Methodology

Step What Detail The goal of this process step is to execute the Notification review methodology selected in the previous process step to obtain additional Notification information. To execute the Notification review methodology perform the following: Action the methodology selected in the previous process step to ensure the following: - where a Task List is required, identify an available Task List that contains the relevant detail for Planning - where a Task List is required, but does not exist, ensure the following information is gathered: - tasks to be performed sufficiently described - materials required sufficient for the job - services required sufficient for the job - labour required sufficient for the job - other requirements, e.g. HSEC, Isolation, etc. - where Item details are required identify required detail Notification Item and Item Classification information
How
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The outcomes of this activity will be inputted into the Notification in the following process step.
305.02.01.180. Update Notification

Step What Detail The goal of this process step is to update the Notification with User Status 'INF' (Additional Scope Required) with information obtained during the review process. To update the Notification, locate the Notification by using transaction Change Notifications (Selection List) and complete only the following fields: Outstanding Select Stats included INF (Additional Scope Required) Main Work Center Enter the Main Work Center responsible for Event/Work Request Planning plant Enter the Planning Plant Execute Transaction and a list of Notifications meeting the above criteria will be displayed. The list may be sorted by Technical Object for ease of review. Select the Notification for processing by selecting the Notification line, then Clicking the Details button: update the Notification with the information gathered from the review process. - if a Task List is required to be attached, to search via the Task List tab on the Notification perform the following: - Click on the 'Search task list' button (binoculars) - the 'Display Task Lists: Task List Selection' screen appears with the Functional Location Construction Type defaulting in the 'Assembly' field. Enter the Main Work Center, in the Work Center field, to narrow the search if required - Execute this screen, a list of Task List appears - Review and select the most appropriate Task List by selecting the Task List line and Clicking the Choose (Green Tick) button - if no Task Lists are available, perform the following: - manually Scope the job utilising long text to explain in more detail the reason for the request and the task required, the Notification Coding Scoping Template can be used to aid in Notification scoping - Initiate a Master Data request for the creation of a Task List, if it is likely that the task will be repeated. Upon completion of the additional information, change the User Status from 'INF' (Additional Scope Required) to 'NEW' by performing the following: Click the 'Status Detail' button (blue button with 'i' character situated to the right of the 'Status' field) on the right hand side of the screen in the 'Status with status no' box, select the radio button beside '10 NEW New Notification' Click the 'Back' green arrow button to return to the main screen Save and Exit the Notification.
How
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Name Fatalities Description Defines the number of fatalities that have occurred within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. HSEC Significant Events Defines the number of Events, within the period, with a potential level 4 or higher impact in one or more of the following Impact Types from the BHP Billiton Severity Table: - Health - Safety - Environment - Social / Cultural - Reputation The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Total Recordable Injury Frequency Defines the number of Recordable Injuries (Fatality, Lost Time Injury, Restricted Work Injury, Medical Treatment Injury) per million hours worked (exposure hours) within the period. The frequency, normalised by exposure hours, enables direct comparison between businesses and within businesses over time. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Outstanding Work Orders and Notifications Compares the number of outstanding Notifications and outstanding Work Orders to the number of open Notifications and open Work Orders.
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Level 3: 305.02.02. Plan Work

Work planning is undertaken for approved Planning Notifications or system generated Work Orders. All system generated Work Orders are reviewed for completeness. A pre-scheduling Priority is assigned to reflect commitments to a day with service providers and for equipment availability. Work Orders are rough-cut scheduled and once fully planned the Work Order is Released, triggering Inventory, Procurement and scheduling.
Process Components
Figure 1: Process Components Component Create Planned Work Description The purpose of this component is to describe the steps involved in creating planned Work Orders. The purpose of this component is to describe the steps involved in updating resource requirements for planned Work Orders. The purpose of this component is to describe the steps involved in pre-scheduling planned Work Orders.
Update Work Order Resource Requirements Pre-Schedule Work Order and Release

Key Concepts related to Plan Work process are outlined in this section. Concept Review Work Order Resource Requirements Description A Work Order contains relevant and detailed information at the Header and at the Work Order Operation to ensure that the work can be executed as required. A detailed Work Order will include: - a complete and precise Work Order Header is mandatory; the final Work Order long text is to contain the context, purpose and desired quality of the task to be completed. - sufficient resources and time within the Work Order Operations to ensure all ramp down, ramp up, administrative and quality requirements are fulfilled; this may include planning for hold points. Note: When all Work Order requirements are satisfied, delete the Notification scoping template from the Work Order long text to prevent it from printing out with
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the Work Order. Pre-Schedule Future Work with Production The Pre-Scheduling meeting is held to align the Work Management and Production schedules: - Production: To confirm Production priorities and dates - Work Management: Allow planning accuracy for future work in advance - Supply: As required to ensure all delivery schedules can be met - HSEC: As required to discuss safety requirements to be included in Work activities. The following tools are required to conduct a successful meeting: - published Production Schedule - Major Events Calendar - list of upcoming Work Orders. Why is the Plan Work The process is triggered when Priority 3 (Planned) Notifications are Approved, Process Important to BHP when Work Orders are generated from a Work Plan, or by a Repairable Work Billiton? Order created by Supply (PM04). Work Orders are created from a Work Plan, an approved Notification, or through the Refurbishment process by Supply. Resources are populated from Task Lists wherever possible. Work Order costs are collected within each Work Order. Once planning is completed, the Work Order is Released. This allows for Reservations and Purchase Requisitions to be processed. Work Orders All activities qualifying as being Work Management relevant, no matter how insignificant, must be executed on a Work Order primarily to ensure that all Work Management activities are managed in a safe, controlled, consistent and transparent manner. The execution of work extends to all functions and related personnel using the Work Management process. Although an employees Position Description outlines the responsibilities that they are to complete as part of their employment, where those responsibilities are covered by the Work Management usage of Work Orders, then Work Orders are used for the execution of those activities. Many persons will be using the same process for different execution reasons; in a similar way that many personnel use the Supply process to procure goods for different reasons. Work Order Considerations As the design for Work Orders is based on expected actions that occur according to the process, for example Authorisations and Settlements, the following considerations are applicable: Work Order Types are selected at creation and cannot be changed if an error is made in the selection of Work Order Type, then the Work Order is to be Completed (Technically Completed TECO or Closed CLSD) and a new Work Order created. settlement Rules will not be manually maintained (The only exception to this is the PM06 Work Order, using the WBS Element field on the Location tab); this ensures that the predetermined Cost Structure is used. Any changes to Work Order costing, is to be through the initiation of a Master Data request to update the Functional Location Cost Element. 1SAP does not allow Standing Work Orders, nor does it support the use of dummy Work Orders; defined Work Order Types, in line with the process, are to be utilised to ensure that all work is controlled in the correct manner with accurate task history captured. to ensure that Planner Controllers remain focused on the preparation of the Weekly Work Schedule, Planner Controllers do not have access to create or change any PM03 Work Order. to ensure that Work Managing Global Job Group holders remain focused on the execution of the Weekly Work Schedule, they do not have access to create PM01 or PM06 Work Orders; however change access is allowed.
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there is no access to any Global Job Group for the manual creation of PM02 Work Orders. Work Order Operations Planning and Scheduling primarily occurs at the Work Order Operation level; each Work Order must be broken down into Work Order Operations that represent discrete elements of the job. Work Orders with numerous Work Order Operations will be rare as the granularity of the Work Order will limit the number of Work Order Operations (e.g. a Work Order which requires an inspection to be performed daily must be constructed with a Work Order Operation for each day, rather than one Work Order Operation with extended duration); on the other hand, Work Orders require sufficient Work Order Operations to effectively execute the required task. Each Work Order Operation must have: a Work Order Operation Description resource Work Center (Tasks requiring execution by different resources must be identified as separate Work Order Operations) Correct Control Key Internal or External Resources planned time for resources (Labour estimates and Duration) required Materials and Services additional information (in the form of work procedures linked to the Work Order Operation as a Document Production Resource and Tool when the Work Order long text is insufficient. The Document Production Resource and Tool will contain the information that is required to carry out the work safely and efficiently) Work Order Operation relationships to support Work Scheduling, where relevant. Immediate & Urgent Task Schedule Interrupt Work is only permitted to be executed on a PM03 or PM04 Consideration Work Order; on the other hand Planned Work is only permitted to be executed on a PM01, PM02, PM04 or PM06 Work Order. This separation is to ensure the correct Global Job Group is accountable for the Work Order requirements. In the majority of instances that an Urgent or Immediate Priority PM03 Work Order is commenced, it will be completed within the same Schedule Period. In the instance that a task on an Urgent or Immediate Priority Work Order is required to extend over a number of Schedule Periods, the following is relevant: for an urgent or immediate task that can be made safe and the additional work can be Planned and Scheduled in a future Schedule Period: - the equipment is made safe or stable - a new Notification is created for the additional work - a PM01 Work Order is created for the new Notification, and it is Planned and Scheduled into a future Schedule Period. for a long duration urgent or immediate task, where the work is to continue uninterrupted into the next Schedule Period, the Schedule for that Schedule Period is yet to be finalised and sufficient time is available to thoroughly Plan the work for Scheduling: - a new Notification is created for the ongoing additional work - a PM01 Work Order is created for the new Notification, and it is Planned and Scheduled into the next Schedule Period - the PM03 Work Order is to be used until Sunday and the PM01 Work Order will be used from Monday. for an urgent or immediate task, where the work is to continue uninterrupted into the next Schedule Period, the Schedule for that Schedule Period has been finalised or insufficient time is available to thoroughly Plan the work for Scheduling: - a new Notification is created for the ongoing additional work, if the work will continue into Schedule Period +2 - a PM01 Work Order is created for the new Notification, and it is Planned and Scheduled into the Schedule Period +2, if required
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- the PM03 Work Order is to be used until the completion of the urgent or immediate task or used until the following Sunday where the PM01 Work Order will be used from the subsequent Monday. Work Center Utilisation Capacity Relevant Resource Work Centers are Work Centers that carry the required Capacity for Planning and Scheduling. Resources that are Scheduled to a Capacity Relevant Resource Work Center will confirm their time to their own Work Center. Capacity Relevant Resource Work Centers are utilised on Work Orders to fulfil the Work Orders labour and non-labour requirements. Accurate Resource Work Center Capacities ensure visibility of resource availability. A worked example is as follows: it is determined that additional resources will be required in a future Schedule Period to execute the required work due to an outage; the BHP Billiton Work Center requires 16 resources for that period. It is agreed that the Long Term Resource Contractor Work Center will loan the Internal BHP Billiton Work Center 6 Resources for the period of the outage. 6 of the Long Term Resource Contractor Work Center Resources are moved to the Internal BHP Billiton Work Center for Planning and Scheduling. The Capacities of each Work Center are adjusted accordingly. the Planner Controller for the area of the outage now Plans and Schedules work for the future Schedule Period to the Internal BHP Billiton Work Center, as this is where the Capacity now resides, hence this is the Capacity Relevant Work Center for Planning and Scheduling work in this outage. for another Planner Controller who is Planning and Scheduling for the same or another Schedule Period (or the same Planner Controller Planning and Scheduling for another Schedule Period), the Long Term Resource Contractor Work Center would still be Capacity Relevant as there has been no move of Capacity to another Work Center and the Long Term Resource Contractor Work Center is Planned and Scheduled accordingly. Where there is no move of Capacity the Long Term Resource Contractor Work Center remains Capacity Relevant for Planning and Scheduling. therefore, a Work Center is determined to be Capacity Relevant, not by a Master Data update, but rather by the perception of the user. as the each Work Center has its own Cost Center relationship, on Time Confirmation all resources Time Confirm to their Work Center of origin to ensure that the costs flow from the appropriate sending Cost Center to the receiving Technical Object Cost Center. Resource Work Center Capacity requirements are determined from the Work Strategies for the Technical Objects; the Work Strategies drive the Weekly Work Schedule. Internal resources are represented in 1SAP by Internal Resource Work Centers; these Resource Work Centers contain Capacities associated with the group they represent. Each Work Order Operation allows time estimates to be entered against the required Resource Work Center. Resource Work Center Capacities must be maintained in order to give a true representation of the available labour resources. Maintaining visibility of the availability of resources within a Resource Work Center is essential to Scheduling Work Management relevant tasks. The intent is that all Work Management tasks are executed using a Work Order where the task is: Executed by a Capacity Managed Resource Executed by a Non-Capacity Managed Resource, where that task impacts or requires visibility on the Work Management Weekly Work Schedule, in support of the Work Management Group Level Document. Service/ Support (S Type) Work Centers are to be created to represent
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Non-Activity Costed Resources, including Labour and non-labour. S Type Work Centers may be created for BHP Billiton owned equipment that does not require an Activity Rate for charge out. This may include workshop machines and lifting equipment. Work Center Assistants & Work Center Assistants and Apprentices assist other Resource Work Center Apprentices members with the execution of their tasks and therefore form part of the Work Center Capacity for the Resource Work Center they assist. With regards to the application of the design for Resource Work Centers for Work Center Assistants and Apprentices the following is relevant: the Resource Work Centers, for which the Work Center Assistants and Apprentices support, contain the capacity of the Work Center Assistants and Apprentices. - note: Only those Apprentices that are authorised to work independently are to be assigned to a Resource Work Center for Scheduling. Until an Apprentice is permitted to work independently, they must not be assigned to Work Order Operations. the Activity Rate for the Resource Work Centers, for which the Work Center Assistants and Apprentices support, will contain the cost of the Work Center Assistants and Apprentices. Activity Costing To ensure that accurate costs accumulate for equipment, Activity Rates are determined through consultation with Finance. The calculation of the Activity Rate takes in consideration that the Resource Work Center is a business and the charge out rate is to cover its operating expenses. The Activity Types that represent the cost associated with use of the resources is not a reflection of Salaries/Wages; the Activity Rate is to be regularly reviewed. Four Resource Work Center Types are available for use in Work Management: M Maintenance P Production X Long Term Resource Contractor S Support Services. All resources that are assigned to an M, P or X Resource Work Center will be Activity Costed by the assignment of an Activity Type and Cost Center. This Activity Type, in relation to the Cost Center, sets the Activity Rate, which is the hourly cost associated with the use of the Resource Work Center. When a Resource Work Center has a resource usage estimate placed against it within a Work Order, SAP calculates the cost of using that volume of hours for the resource. This cost represents the Planned Cost and is determined from the sum of all resource costs. The Activity Rate may be determined using the following as a guide: A / (0.75 H) Where: A = Total value of Purchase Order for Long Term Resource Contractor or Direct Labour Cost Center Actual Costs H = Total Hours requested in the Purchase Order for the Long Term Resource Contractor or Planned available hours of BHP Billiton employees for the Cost Center 0.75 = Multiplier to calculate available hours; this is based on the inclusion of time in the rate for: - breaks - unavailable time - supervisor labour costs.
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Minor adjustments to this calculation may be required over time to ensure the Cost Center is as close to zero as possible at month end; at month end the difference between budgeted costs on Direct Labour Cost Center and the Actual Costs is calculated and the over/under-absorbed costs is redistributed to the Receiving Cost Centers. Employees with Non-Activity Costed salaries, included in S Resource Work Centers, have no Activity Rate. An employee with a Non-Activity Costed salary may be required to perform a dependent task, as part of the Weekly Work Schedule and therefore require a Resource Work Center for visibility (e.g. inspect weld quality).
Activities
Activity Description Work Order Resource Planning The objective of this activity is for the learner to: - obtain an estimate from the Vendor, if required, for the planning of a Work Order - assign a relevant Task List to a Work Order where there is a requirement to change the assigned Task List or add a Task List where no Task List was referenced in the Notification - update the Work Order with basic data, including Work Center Resources - update Work Order Operations with Catalogued Materials if a requirement has been determined - assign Free Text Material requirements to a Work Order that has had Non-Catalogued requirements determined - update Work Order Operations with E-Catalogued Materials if a requirement has been determined - update the Work Order Operations with Document Production Resource Tools to support the work execution - create a Purchase Requisition for a Service on a Work Order Operation for a defined Scope of Work or Rental of Equipment - review the fully resourced Work Order to determine that all requirements have been met.
Component : Update Work Order Resource Requirements 305.02.02.040. Determine Estimate Requirements
Step What Detail The goal of this process step is to obtain an estimate from the Vendor, if required, for the planning of a Work Order. The estimate will drive the Release Workflow of the Purchase Requisition once created with an accurate Estimated Value. To obtain determine estimate requirements, from a Work Order from the previously obtained list, select the Work Order line and Click the Details button. To revie w a specific Work Order, enter the Work Order using transaction 'Change Work Order'. Review the requirements for the purchase of Services or Materials already on contract
How
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or for a Requisition line item less than the prescribed Group Level Document limit, the following applies: where a Purchase is On-Contract, the Vendor can be contacted directly, with the Scope of Work, to enable the Vendor to reply with a detailed estimate, in line with Outline Agreement where a Purchase is not on contract, obtain an estimate from a Vendor. Whilst in the Work Order that is currently being processed, using transaction 'Change Work Order' phone, email or Fax the Vendor with information containing detailed and relevant specifications, including required Services/Material delivery timeframe. if there will be a delay in receiving the estimate from the Vendor and the Work Order will be saved and exited prior to being able to add the Service or Non-Catalogued Material Requirement then: - set the 'RFE'(user status description) User Status which will prevent the Work Order from being Released and flag that this Work Order has pending Planning requirements due to waiting for a Vendor estimate - once the Vendor Estimate has been obtained and the estimate is acceptable, remove the 'RFE' User Status and proceed with the Planning of the requirements. Where the estimate obtained does not meet requirements, the Work Order requirements are to be reviewed and new estimates or alternative arrangements are to be made. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.02.060. Determine Basic Work Order and Operation Data Requirements

Step What Detail The goal of this process step is to update the Work Order with basic data, including Work Center Resources. This requirement can be updated by: - updating the requirements for a Capacity Relevant Resource Work Center on an Operation - adding a new Work Order Operation with a different Capacity Relevant Resource Work Center. Resources are represented by Capacity Relevant Resource Work Centers which have Capacity and Scheduling information. Four types of Capacity Relevant Resource Work Centers exist: - Capacity Relevant Resource Work Centers that represent BHP Billiton Production Personnel (P) - Capacity Relevant Resource Work Centers that represent BHP Billiton Maintenance Personnel (M) - Capacity Relevant Resource Work Centers that represent BHP Billiton Support Services Personnel (S) - Capacity Relevant Resource Work Centers that represent Contractors which satisfy the Long Term Resource Contractor requirements (X). How To update Work Order Operation basic data consideration is given that Work Center Resources on a Work Order Operation are only Resources represented by Capacity Relevant Resource Work Centers which have Capacity and Scheduling information. Resource Work Centers that are Non-Capacity Relevant are only used for Time Confirmation Purposes. A Capacity Relevant Work Center must be visible on the Work
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Order to enable mobilisation. Work Order Requirements are obtained from: - from the Work Order Long Text (which was copied from the Notification on creation). Any Work Order Long Text that is redundant after the Planning of the relevant Work Order Operations is to be deleted from the Work Order Long Text. The final Work Order Long Text is to contain the Context and Purpose of the task to be completed. Quality, Quantity, Resources and Time requirements are contained within the individual Work Order Operations - in consultation with Engineers, Supervisors, Technicians, Subject Matter Experts, Planner Controllers - from the Notification Generic Object for Services (GOS) uncontrolled documents attached to the Notification to assist in planning activities. Review attached information and update relevant Work Order Operations with information with regards to personnel and timing requirements. Planning of a Work Order and Work Order Operation requirements includes any pre-work and preparation tasks to be performed by any Work Center, resources to execute the desired task and any post-work and demobilisation tasks to be performed by any Work Center. These resources are included in consideration of the Fatal Risk Controls Group Level Document. The Work Order is to be resourced to include: - Production activities including isolation and area/equipment preparation - the set-up and dismantle of the work area - placing and removal of local isolations - set-up and removal of all support equipment and temporary structures, such as scaffolding - resources to perform the desired task - resources to ensure the work site is left in a clean and safe condition, which may involve leaving certain equipment in place, including fire fighting equipment and lighting, until isolations are removed - quality evaluation requirements, including hold points. Work requirements are included to ensure completion to a satisfactory standard based on Operation and technical specifications. The Supervisor, work crew or relevant inspector may be included in the inspection. Planning of the de-isolation equipment is to follow the Fatal Risk Controls Group Level Document and prescribed Asset/Operation requirements. Once the isolations are removed, final demobilisation may be possible, including: - fire fighting equipment and lighting left in place to allow safe de-isolation - include the resources required for handback of equipment to Production. Where applicable, an allowance for commissioning on start up to ensure equipment is functioning as required - include the requirement of the cleaning, packaging and meeting of Supply requirements for the return of Repairable Spares/Service Exchange Items - Production activities including de-isolation and area/equipment preparation for production - an allowance of time for the management of the administrative Work Order requirements (Time Confirmations, Material Return requirements, history recording, etc.) - non-generic safety requirements. These may include: PPE (acronym), monitors, etc. To update a Work Order from the previously obtained list select the Work Order line and Click the Details button. To review a specific Work Order, enter the Work Order using transaction 'Change Work Order'. To update the requirements for a Capacity Relevant Resource Work Center on a Work Order Operation: - select Work Order Operation that requires additional Labour
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- update the Duration - update the Number (of resources). To update the requirements of a new Operation: - select Capacity Relevant Resource Work Center to be used on the new Work Order Operation - check Control Key is PMIN (description) and change if necessary - provide a clear Description of the work required. Long text can be utilised to help clearly articulate the work description (this will require an update of the default Description in Operation 0010, which is a copy of the Work Order Header) - update the Duration - update the Number (of resources). To update the requirements of a new Operation: Select Capacity Relevant Resource Work Center to be used on the new Work Order Operation. if the personnel to execute the work is identified and is assigned to the Work Order Planning Plant, but the assigned Work Order Operation work center is not known perform the following: Clear the Work Center field (delete value) Highlight the operation and Click on the Internal button on the Internal Processing screen, delete any value in the Work ctr field, and then Click in the Person. No. field, then Click on the possible entries search button when it appears to the right of the field. on the pop-up screen, press continue to list the personnel assigned to all work centers in the same plant if further filtering is required Click on the binoculars to search for a specific personnel number or name when the persons name is located, note their work center and cancel the pop -up window. Ensure that no personnel number is populated in the Person. No field. Return to the Operation Overview screen and enter the previously identified and noted work center value in the Work ctr field if the personnel to execute the work is identified, but either the Person is assigned to a different maintenance plant and their Work Order Operation work center is not known, or the Person is assigned to a different maintenance plant and their Work Order Operation work center is known, perform the following: Clear the Work Center field (delete value) Highlight the operation and Click on the Internal button on the Internal Processing screen, delete any value in the Work ctr field. in the Plant field (directly to the right of the Work ctr field) delete any current value, then perform one of the following: Enter the Maintenance Plant identifier of the person if known for maintenance plants that begin with a letter enter the first letter of the maintenance Plant followed by wildcard symbol () for Maintenance Plants that being with numerals enter the first two digits of the Maintenance Plant followed by wildcard symbol () Click in the Person. No. field, then Click on the possible entries search button when it appears to the right of the field. on the pop-up screen, press Continue to list the personnel assigned to the Plants which were searched for. if further filtering is required Click on the binoculars to search for a specific personnel number or name. when the persons name is located note their work center and Maintenance Plant then cancel the pop-up window. Ensure that no personnel number is populated in the Person. No field. on the Internal Processing screen enter the persons previous ly identified Work Center in the work ctr field and their Maintenance Plant in the Maintenance Plant field. Then select the Enter key,
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Return to the Operation Overview screen where the Work Ctr field has been populated. Check Control Key is PMIN and change if necessary in the Operation short text field provide a clear description of the work required. The Notification Long Text will assist in this activity. long text can be utilised to help clearly articulate the work description (this will require an update of the default Description in Operation 0010, which is a copy of the Work Order Header) Update the Duration Update the Number (of resources). The system compares the Capacity requirement for the Work Order Operation against the Capacity defined for the Resource Work Center and will give a warning if the Capacity is exceeded. Work Order Operation relationships are used with the following considerations: - where a task is a precursor or successor to an activity, Work Order Operation Relationships are to be maintained between the impacted Operations. The inclusion of hold points is to be also addressed during the Work Order Operation planning - review and set Work Order Operation relationships to ensure that when Material requirements are linked to the Work Order Operations their requirement dates will be set based on the correct relationships between the Work Order Operations. To set Work Order Operation relationships the following is relevant. To create inter-Work Order Operation relationships: - from the Operations tab select the Work Order Operations that require a relationship set - Click 'General' button and then select the 'Relationships' tab, complete the following fields: - OpAc - (Operation Activity), Enter the Work Order Operation to which this Work Order Operation has a relationship - Offset to finish - Enter the duration between relationships if applicable - Un. - Enter the unit of measure (hrs or days) - Ty. - Enter the Relationship type (e.g. Setting a Finish-Start 'FS' relationship will indicate that the Work Order Operation currently being processed is a successor to the Work Order Operation entered into the Relationships tab), Start-Start 'SS' may also be set - Order - Enter the Work Order that contains the Operation to which this Work Order Operation has a relationship - use the 'General' tab to confirm the Work Center, Control Key and Status of the selected Work Order Operation while setting Work Order Relationships. The 'Dates' tab will show the Earliest Start and Earliest Finish dates and times and Latest Start and Latest Finish dates and times, this is used when setting relationships as it shows the start and end dates and times and also the lag time. The Actual Start and Actual Finish dates and times show if a Work Order Operation has been started (has a PCNF status)(partial confirmation) or is completed (has a CNF status)(final confirmation). If a Work Order Operation has been started, the Earliest Start date cannot be moved. To schedule these Work Order Operations in MRS, the whole Work Order Operation duration is scheduled. In the case when part of the work in the Work Order Operation has been completed, a new Work Order Operation is to be created with the remaining work outlined and the original Work Order Operation will need to be Finally Confirmed (CNF). To create intra-Work Order Operation relationships: - from the menu path select Goto > Graphic > Network structure. From within this view, inter-Work Order and intra-Work Order relationships are visible and able to be manipulated - Click the 'Connect' button to enable the relationship drawing tool - Move the Work Order Operations into a logical grouping representing the required
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relationships and draw the required connectors (e.g. SS, FS, SF) - on completion of relationship setting, Click the 'Schedule' button, this will outline any Schedule conflicts or Work Center deficiency that may have been introduced when setting relationships in the Schedule log, this log is refreshed when the Work Order is saved, so the log must be viewed prior to saving - Click 'Back' button to return the Work Order processing view (Save Node Item if prompted to do so). The 'Schedule' button will update the information within the Graphic Network Structure and highlight any schedule conflicts or loops. If additional Capacity is required to be added to the Resource Work Center to enable this increase in Resource, the Capacity should be increased on the Resource Work Center, this is covered in the Scheduling process. Work Order Operation User Status is automatically assigned from the associated Task List and cannot be changed. The usage is as follows: - the Safety Critical SFC indicator is set on all Work Order Operations for work on Safety Critical Elements which contribute to the achievement of the Performance Standard for Material Health, Safety, Environment or Community Risks. The Safety Critical SFC indicator is not set on Work Order Operations for work on Safety Critical Elements which does not contribute to the achievement of the Performance Standard - the Business Critical BSC indicator is set on Work Order Operations for those tasks that contribute to the achievement of the Performance Standard for Material Risks that are not Health, Safety, Environment or Community related. The Business Critical BSC indicator is not set on Work Order Operations for tasks which do not contribute to the achievement of the Performance Standard for non HSEC related Material Risks - no Criticality is set due to a non-Business Critical and non-Safety Critical activity (the work does not contribute to the achievement of any Performance Standard). The installation or removal of a Linear Object within a Functional Location will require the initiation of an MDM Request to change the Functional Location Characteristics. Mobilisation of Non Permanent Long Term Resource Contractor To mobilise Non-Permanent Long Term Resource Contractor, a process will need to be in place at individual Customer Service Groups, to ensure the Vendor is aware of the requirements to engage their Resources, as they will not receive a Purchase Order detailing the individual tasks to be performed for each service. The work to be performed by these Long Term Resource Contractors will be on the Work Orders and identified during the Scheduling process, an electronic or hard copy of the Work Orders would be sufficient for the mobilisation of this Contractor Group, although an initial phone call may be required. A Contract and Purchase Order will be in place with Vendor, indicating the BHP Billiton Commercial Requirements, the work quality specifications and Site access procedures. Resourcing Investigations All Investigations must be assigned a Task List which is resourced in line with the following requirements: - Plan Investigation - Assigned to the Resource Work Center of the Risk Owner (person) for the Event or Issue (consult the Investigation Protocol for guidance on identification of the Risk Owner) - Execute Investigation - Assigned to the Resource Work Center of the Risk Owner (person) for the Event or Issue (consult the Investigation Protocol for guidance on identification of the Risk Owner). The Risk Owner may request reassignment of this Work Order Operation at a later stage - Review Investigation - Assigned to the Resource Work Center of the Risk Owner's Manager (person), (consult the Investigation Protocol for guidance on identification of the Investigation Reviewer).
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Additional Work Order Operations may be assigned at this stage or later in the Investigation process. The Work Order Operations of Plan Investigation, Execute Investigation and Review Investigation must be executed for all Investigations. Responsible Cost Center Main Work Centers will be defaulted from the Reference Technical Object onto the Notification on creation. When a Work Order is created for a Notification the Responsible Cost Center is defaulted from the Main Work Center to the Responsible Cost Center field in the Additional Data Tab on the Work Order. It is this Responsible Cost Center that is used to set the Workflow logic for approval of Purchase Requisitions and Service Entry Sheets on the Work Order. The defaulting of the Responsible Cost Center from the Main Work Center on the Work Order Header is only carried out at creation of the Order; subsequent changing of the Main Work Center on the Work Order will not update the Responsible Cost Center; to manually update the Responsible Cost Center, enter the correct Cost Center into the 'Responsible CCtr' field on the Additional Data tab of the Work Order. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.02.070. Determine Catalogued Material Requirements

Step What Detail The goal of this process step is to update Work Order Operations with Catalogued Materials if a requirement has been determined. This includes the automatic creation of a Negative Reservation for the return of Repairable Spares and Service Exchange Items to ensure the damaged Material is returned to Supply for repair. To update Catalogued Materials on a Work Order from the previously obtained list select the Work Order line and Click the Details button. To review a specific Work Order, enter the Work Order using transaction 'Change Work Order'. Materials are Reserved on either on the Components Tab of the Work Order or alternatively on the Components Tab of each individual Operation. Work Order initiated Reservations are created for Plant Spares and consumables which reasonably be entirely consumed in the execution of the Work Order, on the task for which the Work Order was created. Catalogued Materials may be added to a Work Order by: - selecting from a Material search (TREX is available for advanced searching (e.g. Manufacturer's Part Number). In the Component field Click the Possible Entries Search button, make sure the Advanced Search for Material Using Search Engine screen displays, perform the search) - selecting from the Structure List (Clicking List button) - selecting from an alternate Assembly (Clicking the Assem. button) - manual entry of Catalogue number. Steps for entering Catalogued Material: - Component - Enter Catalogued Material Number - Reqmt Qty - Enter Quantity - SLoc Enter the Storage Location - Recipient - Enter the Recipient (Free Text line) - Unloading Point Enter the Unloading Point (Free Text line)
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- Manual Requirement Date When selecting this option the 'Reqmt Date' field will be locked and Rescheduling the Operation will not affect the Date This option is selected when the component requirements are required on site prior to or after the Operation Start Date. Consideration is to be given to the lead time of the materials and the delivery requirements. Early delivery of Materials may cause storage issues to develop. Repairable Spares and Service Exchange Items are identified by a Batch field of 'CAPITAL', 'NEW' or 'REPAIRED' on the Component line. When saving a Work Order with a Repairable Spare or Service Exchange Item, the system will automatically assign an additional negative Reservation (in the same quantity of that reserved) for the future return of the Damaged Repairable Spare or Service Exchange Item once it has been removed. The Batch Field shall also be auto updated with 'DAMAGED' and the SLoc updated to 0099. For Capital Materials that are not repairable the values in the batch Field will be 'CAPITAL' or 'SCRAP', when a Non Repairable Capital Material is issued to a Work Order a return line will not be added automatically. This return line must be entered manually and the Batch Field set as SCRAP and SLoc 0099. The returning of the Scrapped Capital Material will initiate the Scrapping Process in Supply and Finance. If Item Category 'N' is defaulted from the User Exit determination on Material MRP settings or BOM then the following Purchase Requisition Details may also need to be entered, if not defaulted from the Material Master and Source List: - Goods Recipient - Unloading Point - Vendor (if known). Purchase Requisition data defaulted from Material Master and System Configuration: - Price - Material GroupPurchasing Group and Purchasing Organisation - Planned Delivery Time. With regard to Catalogued Materials, the following considerations are relevant: - catalogued materials with the MRP type of V1 or PD are Inventory managed and the default tem category will be set as 'L', this will create a Reservation and MRP will create the Purchase Requisition if the Material is not kept in stock. In the instance of a Repairable material with the MRP type of PD being Reserved, a negative Reservation will also be required to be created to return the damaged item removed from the plant for repair, before the fulfilling of Reservation once the sub-contract repair is complete - for Catalogued Materials with the MRP type of ZD or ND, the item category will be automatically set to 'N', this will create a Direct Purchase Requisition. These Catalogued Materials will generally be on a source list and as such will be linked to an Outline agreement and a Vendor; the Purchasing Data will be defaulted into the Purchase Requisition. Materials that are linked to Source lists are automatically purchased. These Materials are consumable items only and as such do not represent operating spares. Perform a Material Availability check to ensure the Requirements Date can be met. Should the Material requirements not be able to be satisfied on the date required, adjust the Requirement Dates, and negotiate with other person who has reservation for same Material to enable the issue of Material for this requirement or contact Supply to resolve availability issue. When Work Order Planning has been completed and Work Order Operations Requirements have been met, Reservations and Purchase Requisitions will be created for those Work Orders that have already been Released. To allow initiation of the procurement of materials that are either long-lead to procure or long-lead to replenish, it
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may be required to activate a Reservation prior to Work Order Release; this is done by setting the Res./Purc. req. to Immediately. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.02.080. Determine Non-Catalogued Material Requirements

Step What Detail The goal of this process step is to assign Free Text Material requirements to a Work Order that has had Non-Catalogued requirements determined. Free Text requirements will create a Purchase Requisition when the Work Order is Released or if already Released when saved. To update a current Purchase Requisition for a Non-Catalogued Material or to create a new Purchase Requisition for a Non-Catalogued Material, determine the material requirements. A Free text Material Purchase Requisition is used to create a Purchase Requisition for: Non-Catalogued items for consumption on the task for which the Work Order was created the offsite, non-supervised/managed repair and return of a non-Catalogued piece of plant, for which the dismantle and installation has a requirement to be Planned and Scheduled, or has a requirement for the costs of such to settle to the Cost Center of the Technical Object a requirement from Supply to update a Purchase Requisition on a Work Order due to: - Purchase Requisition being outside of tolerances as specified in the Supply Group Level Document and therefore a Purchase Order cannot be created - Purchase Requisition having its Workflow Approval rejected. To assign or update a Free Text Material to a Work Order Operation, change the Work Order currently being processed or use transaction 'Change Work Order' and enter the Work Order number, select the Operation, Click 'General' button and in the 'Components' tab complete the following fields: Description - Enter the Free Text line in the Component description, long text will appear as long text on the Purchase Order Reqmt Qty - Enter the Quantity Un - Enter the Unit of Measure. Sloc - Enter the Storage Location. In the Component Detail Purchasing screen: Price - Enter the estimated price Purch group - Enter the Purchasing Group Vendor - Enter the Vendor (if known) Goods Recipient - Enter the Goods Recipient (Free Text line) Unloading Point Enter the Unloading Point (Free Text line) Pl. Deliv. Time Enter the Planned Delivery Time (days), the delivery time noted by the Vendor is entered into this field. This value, combined with the Supply default Purchase Requisition Processing time sets the Purchase Requisition Release Date to ensure the delivery date can be met. The Purchase Requisition Release Date is the date when the buyer will see the Purchase Requisition in their Purchase Requisition queue. In the Component Detail General Data screen: Manual Requirement Date When selecting this option the 'Reqmt Date' field will be locked and Rescheduling the Operation will not affect the Date. This option is selected
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when the component requirements are required on site prior to or after the Work Order Operation Start Date.
Particular attention must be paid to the Operation dates as this is what is set as the Requirement date for the Material in the Purchase Requisition and as this Material will need to be sourced and supplied additional time needs to be taken into account to ensure that the Material can be sourced prior to the Work Order being executed. Consideration is to be given to the lead time of the materials and the delivery requirements. Early delivery of Materials may cause storage issues to develop. To allow initiation of the procurement of materials that are either long-lead to procure or long-lead to replenish, it may be required to activate a Purchase Requisition prior to Work Order Release; this is done by setting the Res./Purc. req. to Immediately. To support the estimated price, include all information regarding the acquisition of the price estimate and relevant information regarding the Vendor source in the Text area of the Purchase Requisition, as well as attach any supporting documentation to the Generic Object for Services of the Purchase Requisition. This can only be done after the Work Order has been Released and saved the steps are: from the Work Order being processed Open the Purchase Requisition from the Purchasing Data tab and switch from Display to Change mode any information relevant to the Purchasing Officer, enter this text into Item Note (This text will not be printed on the RFQ or the Purchase Order or the Vendor) any information relevant to the Vendor, enter this text into the Item Text (This text will be printed on the RFQ or Purchase Order for the Vendor) Attach any supporting documentation, obtained from the Vendor or relevant to the Purchase, to the Generic Object for Services. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.02.110. Determine Direct Purchase Requisition Requirements

Step What Detail The goal of this process step is to determine which items are required to be resourced using a Purchase Requisition from within the Supply processes. To create a Direct Purchase Requisition, the Supply processes must be followed. The following items are to be procured using the relevant Cost Center, initiated within the Supply process and not on a Work Order: Non-Catalogued item, the Settlement of which is to the departments overhead Cost Center (e.g. Tools) Repair of an item that is deemed to be an overhead cost (e.g. Repair of a tool).
How
305.02.02.120. Determine Direct Reservation Requirements

Step What Detail The goal of this process step is to determine which items are required to be resourced using a Reservation from within the Supply processes.
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How To create a Direct Reservation, the Supply processes must be followed. The following items are to be procured using the relevant Cost Center, initiated within the Supply process and not on a Work Order: consumable Items, the Settlement of which is to the departments overhead Cost Center lubricants and oils which are not considered to be entirely consumed in the execution of a single Work Order.
305.02.02.150. Review Work Order Resource Requirements Met

Step What Detail The goal of this process step is to review the fully resourced Work Order to determine that all requirements have been met. To determine if the Work Order resource requirements have been met, use transaction 'Change Work Order' and review the requirements which have been added to the Work Order. If the requirements have not been met, the additional requirements are identified initiate additional updates. If requirements have been met for Planned Work for Scheduling, proceed to determine if consideration to future Work Plans is to be given.
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Name Outstanding Work Orders and Notifications Schedule Loading Description Compares the number of outstanding Notifications and outstanding Work Orders to the number of open Notifications and open Work Orders. Compares the sum of hours Scheduled on Work Order Operations for execution by Capacity Managed Resource Work Centers in period, to Capacity Available on Capacity Managed Resource Work Centers in period. Compares the number of system generated Work Orders cancelled in period, to the number of system generated Work Orders completed in period. Compares the number of unfinished system generated Work Orders that are overdue, to the number of unfinished system generated Work Orders.
Cancelled System Generated Work Orders
Overdue System Generated Work Orders
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Level 3: 305.02.04. Execute Work

Work execution includes all preparation, activity execution and post-activities (quality and safety checks before handover). Ensures daily Time Confirmations are completed, handover to the next shift is conducted for ongoing work and return of goods to Store.
Process Components
Figure 1: Process Components Component Prepare for Work Execution Description The purpose of this component is to describe the steps involved to complete preparation activities for work execution. The purpose of this component is to describe the physical execution of work. The purpose of this component is to describe the steps involved in controlling work execution, activities such as shift handover, hand back to production, conducting work quality inspections and ensuring the required catalogued/non-catalogued materials have been returned to the store. Additionally, Time Confirmations are entered.
Work Execution Control Work Execution

Key Concepts related to Execute Work process are outlined in this section. Concept Conduct Required Work Quality Inspections Description Quality work is essential to execution success. Quality may include: - checking correct specifications - checking sufficient commissioning - peer reviews - Supervisor reviews. Time must be confirmed anytime you are engaged in a specific work activity related to a unique Work Order Operation. Any delay incurred during the execution of the work activity, where the resource is not deployed to another task, is Time Confirmed as part of this activity. Do not confirm time when: - having crib breaks
Record Time Confirmations
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- when involved in toolbox talks. A Final Confirmation must only be entered for the last resource on a Finished Work Order Operation. When all Work Order Operations have been Finally Confirmed the Work Order may progress to a completion. For persons without 1SAP access, their manager will co-ordinate Time Confirmations; an upload sheet is available. Ensure that your Resource Work Center is used in the Time Confirmation. Why is the Execute Work A scheduled week starts on Monday and ends on the following Sunday. This Process Important to BHP process is triggered by publishing the agreed schedule (including associated work Billiton? packs), which allocates individuals to daily tasks. This is the physical execution of the work, which includes ensuring preparation, isolations, and other HSEC requirements are satisfied. Any additional resources are secured to complete the work if necessary. BHP Billiton has an overriding commitment to achieve Zero Harm. The work needs to be continually monitored to ensure that the schedule is followed to optimise efficiency. The Execute Work process manages ongoing work and ensures a concise handover to the oncoming shift, if required, and ensures that daily Time Confirmations are completed. Maintaining Schedule Control The following actions must be performed to ensure that the Work Schedule will accomplish the intended purpose: Visible Leadership - spend time in the field, monitor execution safety and quality, progress constraints (remove bottlenecks) - attend the Weekly Scheduling Meetings - check understanding of and empower adherence to the 1SAP Work Management business process. Proactive Engineering - Develop Work Strategy for all Business Critical and Safety Critical Locations - support the Repairable Spare process for all components that are repaired - utilise the Investigation and the Engineering Change processes. Rigorous Planning and Scheduling - establish protocol for Weekly Schedule approval and distribution - audit time scheduled for tasks to ensure that only realistic durations are allowed. Quality Execution - proactively participate in work performance compliance review - complete tasks to expected level of performance - record accurate History.
Activities
Activity Production Handback & Catalogued Material Returns Description The objective of this activity is for the Learner to return catalogued materials.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31947?mode=EU Prepare for Work Execution The objective of this activity is for the learner to: - produce a list of Work Order Operations for execution - establish the HSEC Requirements in accordance with the Operation
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standards and the Fatal Risk Controls Group Level Document - confirm the availability of resources required to execute the work.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.34124?mode=EU Perform a Single Time Confirmation The objective of this activity is for the learner to perform a single Time Confirmation.
Component : Prepare for Work Execution 305.02.04.010. List Work Order Operations for Execution
Step What Detail The goal of this process step is to produce a list of Work Order Operations for execution. Where printed Work Packs (Work Order Form including attachments) have been compiled and issued to the Supervisor for distribution to individuals, or teams who will execute the work, these are used for an understanding of all work requirements. The listed Work Order Operations will be for a combination of the following work: - work scheduled to commence - work that is to be continued by the same shift - work that has been handed over to this shift for continuation - work that is for urgent execution - work that has been rescheduled in current period - work that had resource issues which have been resolved. To display a list of Work Order Operations for execution use the transaction 'Change Work Orders and Operations (Selection List)', with the following criteria: - by Main Work Center. In the 'Order Header' Tab: - In process - Select - Main work Center - Enter relevant Main Work Center - Plant work Center - Enter Plant. - by Main Work Center. In the Dates Tab: - earliest start date - Leave Blank - earliest start date to - Enter end of Schedule Period. Execute the transaction. - by specific Resource Work Centers. In the 'Order Header' Tab: - in process - Select - main work Center - Enter relevant Main Work Center - plant work Center - Enter Plant. - by specific Resource Work Centers. In the 'Operation' Tab: - operation Work Center - Enter the Resource Work Center. - by specific Resource Work Centers. In the Dates Tab: - earliest start date - Leave Blank - earliest start date to - Enter end of Schedule Period. Execute the transaction. - by a specific person. In the 'Order Header' Tab: - main work Center - Enter relevant Main Work Center (where required)
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- plant work Center - enter Plant (where required). - by specific person. In the 'Operation' Tab: - operation Work Center - Enter the Resource Work Center (where required) - personnel Number for Split - Enter Personnel number or Personnel numbers to locate work for specific individuals. - by specific person. In the Dates Tab: - earliest start date Leave Blank - earliest start date to Enter end of Schedule Period. Execute the transaction. The executed search will then display a list of Work Order Operations that meet the search criteria. If additional information is required perform the following: - to obtain further information on the Notification double mouse Click on the Notification Number - to obtain further information on the Work Order Operation (e.g. Work Order Operation Long Text, Production Resource /Tools) perform the following: - double mouse Click on the Work Order Number. The Work Order will then be displayed. Click on the Operations tab to display all of the Work Order Operations - the Production Resource / Tool check box will be ticked if a Production Resource / Tool is attached to the Work Order Operation. To return to the list of Work Order Operations Click the Exit button (yellow arrow at top). Click No when the prompt appears to save any changes. The Revision is not used in the selection list because PM03 Work Orders do not have a Revision assigned and would therefore not be displayed in the results. HSEC requirements are also identified, these may include: Safety Permit requirements, Toolbox delivery, Additional PPE requirements, Gas/Safety Monitors. To determine correct sequence of Work Order Operation execution, the Work Packs (Work Order Form including attachments) and the published Work Schedule are referred to. If executing the Work Order without a hard copy Work Pack, within the Work Order select Menu path > Order > Print > Order. Select the Job Ticket and Click 'Print Preview'. The Work Order and attachments can be viewed electronically. To view attachments on the Work Order, from the Operations tab perform the following: - in the Operations Tab, Select the Work Order Operation, Click 'Prod. Resources/tools' button - from Production Resource /Tool list Select Document Information Record, Select Menu Path > Environment > Display Production Resource/ Tool, Select Document and Click 'Display Original' button. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.04.020. Establish HSEC Requirements

Step What Detail The goal of this process step is to establish the HSEC Requirements in accordance with the Operation standards and the Fatal Risk Controls Group Level Document. To establish the HSEC Requirements, refer to the Fatal Risk Controls Group Level Document and the applicable Operation standards.
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305.02.04.030. Confirm Resource Availability

Step What Detail The goal of this process step is to confirm the availability of resources required to execute the work. It is undertaken prior to work commencement. This includes confirming the materials, labour, services, and equipment availability. To confirm resource availability may require communication with multiple departments. To confirm resource availability, use the Work Order Operation list produced in the previous process step and the Work Packs (Work Order Form including attachments). Although work lists are produced daily, confirmation of resources may need to be undertaken in advance of the scheduled day (e.g. confirm all Materials at beginning of Schedule Period and only confirm exceptions thereafter). Check, that for each Work Order Operation, the detailed resources are available: the crew attendance is known, and any absences that will impact on the execution of work as Scheduled are identified using the published Weekly Work Schedule where pool labour or labour hire are required to support the work execution, they are contacted to confirm availability as planned for work requiring the use of services, Vendors are contacted to confirm availability as planned. Where advanced set up is required, it is confirmed that this has occurred confirming of simultaneous activities is confirmed including co-ordination with Production, and other work execution in the vicinity. To confirm Materials and external Service availability select and open the relevant Work Order access the Materials Tracking from the menu path > Environment > Material Tracking. Note: Hover the cursor to the header of the traffic light column to display the long description of the traffic light status. There are two levels for traffic lights: high status traffic light represents the highest level of status of any of the Services/Components requested on the Work Order/Purchase Requisition low status traffic light represents the lowest status of any of the Services/Components on the Work Order/Purchase Requisition Procurement Process traffic light levels: Procnt documents High Procnt documents Low Procurement traffic lights meaning: Green led Indicates that the component or service has been issued or delivered Yellow led Indicates that the component or service has been ordered Red led Indicates that the component or service has not been ordered Requirement traffic light levels: Reqnts analysis High Reqnts analysis Low Requirement traffic lights meaning: Green led Indicates delivery on time Yellow led Indicates critical delivery Red led Indicates late delivery
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Any issues that have arisen and that will affect execution as planned are identified for resolution. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.04.050. Participate in Daily Pre-Start Meeting

Step What Detail The goal of this process step is to ensure that all personnel executing work understand their work requirements, including the implementation of all HSEC and Production requirements, prior to work commencement. The Adherence to Schedule on Day results for their previously worked shift is also discussed. To participate in the Daily Pre-Start Meeting, the Work Supervisor has prepared the results for the crew's previously worked shift's Adherence to Schedule on the Day results; the results are to be discussed at the daily Pre-Start Meeting. Once per week, the Work Management performance results that have already been reviewed for the previous week are also to be discussed with the work crew, these include: Planned & Scheduled Work Adherence to Schedule Finished Within the Week Time Confirmation Compliance Zero Hour Confirmations Compliance to Work Plan. Any specific issues are to be addressed with the Work Crew to ensure that process discipline is obtained in these areas. Prior to work commencement, work crews are to understand their requirements for the day, including HSEC and Production requirements. Any clarity required is to be sought by individual crew members prior to work commencement.
How
305.02.04.060. Identify Production Handover Requirements

Step What Detail The goal of this process step is to determine what Production related equipment handover requirements are necessary prior to work commencement. To execute the work, the Work Order and any attachments are referred to, to determine the relevant Handover requirements. Some activities may not require the equipment to be handed over from Production (e.g. Non-Process area work activities).
How
305.02.04.070. Conduct Handover from Production

Step What Detail The goal of this process step is to confirm that equipment handover from Production is conducted as per Operation requirements and Fatal Risk Controls Group Level Document.
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How
To conduct equipment handover from Production, Fatal Risk Controls Group Level Document and Operation requirements must be complied with, including: completing handover checklists obtaining appropriate permits.
305.02.04.080. Implement HSEC Requirements

Step What Detail The goal of this process step is to assign individual work responsibilities ensuring required work permits are obtained. For any simultaneous work requirements, a final check of the integration between tasks is to be undertaken. Ensure equipment is isolated as per Fatal Risk Controls GLD and Operation requirements. Perform site preparation as per the Health, Safety, Environment and Community (HSEC) requirements. Effective preparation will assist in the smooth execution of the work in a safe manner. Any HSEC requirements identified previously shall be implemented in this process step. This can include the issue of: - permits to work - Personal Protective Equipment (PPE). The goal of this process step is to assign individual work responsibilities ensuring required work permits are obtained. For any simultaneous work requirements, a final check of the integration between tasks is to be undertaken. Ensure equipment is isolated as per Fatal Risk Controls Group Level Document and Operation requirements. Perform site preparation as per the Health, Safety, Environment and Community (HSEC) requirements. Effective preparation will assist in the smooth execution of the work in a safe manner. Any HSEC requirements identified previously shall be implemented in this process step. This can include the issue of: - permits to work - Personal Protective Equipment (PPE).
How
Component : Work Execution 305.02.04.090. Execute Work Order Operations

Step What Detail The goal of this process step is to perform the physical execution of work in a safe manner. During work execution, additional materials or internal labour may be required to be obtained to enable the work to be completed. It is to be determined what work is required to be completed by the current shift. Work that will continue beyond the end of the current shift needs to be assessed if it will be completed by the current shift, or whether the work will continue into subsequent shifts. The job site is now prepared for shift end. The execution of the Work includes all Work Order Operations on the Work Order and may include Quality Evaluation requirements. To determine the full scope of the activity and execute the work, where available refer to the Work Packs (Work Order Form including attachments) and Weekly Work Schedule. Particular attention is paid to the safety considerations of the task. During the work execution, if any requirements arise that are additional to the tasks being performed, the Supervisor is to be notified before proceeding. Work identified within the original scope may be performed on current Work Order Operations. Work
How
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identified to be not within the original scope must not be executed on the current Work Order. Only resources to complete the original intent of the Work Order Operation are to be included within the requirements for the Work Order Operation, the following is to be considered: - should the additional work required be within the intent of the Work Order, proceed to secure additional resources to that effect - should the additional work be outside the intent of the original Work Order, initiate the reporting of the event or additional work and proceed though the required process for such. To determine if work will carry on beyond end of shift, progress must be evaluated prior to shift end and a decision made based on Scheduling requirements. If the work is required to be completed by the crew on the current shift, the Supervisor is to be notified to initiate approval of additional resources and time required to complete the tasks. To prepare the site for shift end, when work is incomplete but will resume the next day, the equipment is left in a safe and secure state, ensuring that any work area obstructions are minimised whilst the task is on hold. To ensure the equipment is left in a safe condition, 'Out of Service' tags may be required to be placed on appropriate locations in accordance with the Operation procedures and Fatal Risk Controls Group Level Document, while the job is on hold. A Work Order Operation may include a quality Evaluation considering the following: - Work Order Operation User Status (e.g. Safety Critical, Business Critical) - Work Order Priority - HSEC Implications if the work was not evaluated. Proceed to the creation of a Measurement Document to record readings for the following scenarios: - as part of work execution activities where required (e.g. Lost Days Information) - as a result of a post work evaluation activity - as a result of the performance of a Counter-Based service, the recording of the actual counter reading of the equipment at the time of the service being performed - to record component life for all components being tracked due to a Material Risk. The Measurement Document will contain the Serial Number of the installed Material (Where no serial number exists a local plant identifier may be entered in lieu). Proceed to capture Work Activity history where any of the following situations exist: - a Controlled Document is an output of the Work Order Operation - an Uncontrolled Document is an output of the Work Order Operation - a change to Notification Information is required as an output of the Work Order Operation - there is a Legal requirement or Business requirement to record Work Activity history. Where changes are identified during the execution of the work, proceed to initiate any of the following: - Master Data Change request - Engineering Change request - changes to Work Strategy - changes to Operational practices. In the event that a Work Pack is lost or damaged, the option to reprint the Work Pack is available.
Component : Control Work Execution
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305.02.04.100. Conduct Handback to Production

Step What Detail The goal of this process step is to handback equipment to Production after the work is complete. This handback should be in accordance with the Operation requirements. If the work has resulted in changed equipment conditions, this is to be communicated to all stakeholders. To conduct the handback of equipment to Production, the work site needs to be safe and all work completed. Any special conditions applicable to the equipment need to be communicated to Production. Where applicable, commissioning is performed upon start up to ensure equipment is functioning as required. Follow specific Operation procedures for handback of equipment.
How
305.02.04.110. Update Shift Log

Step What Detail The goal of this process step is to record any relevant information that can be useful for the oncoming shift and shall be documented and used in the shift handover process. To update the Shift Log, access the relevant log as determined by the Operation, this document preferably should be electronic format, stored for easy retrieval.
How
305.02.04.120. Update All Stakeholders on Schedule Progress

Step What Detail The goal of this process step is to update Production and other stakeholders on the work progress at a daily meeting. Any delays, additions to scope or difficulties with the task must be communicated to Production to keep them informed. To ensure all relevant parties are aware of Schedule Execution progress, Production and other stakeholders are advised of the work progress to date, including any work that is running over schedule, potential delays, and the possible downstream effects. The condition of any equipment that is out of service at shift end is to be communicated to all stakeholders; this will ensure that all working in the vicinity of the equipment understand any restrictions. This daily meeting is to ensure that correct decisions can be made on Schedule Adherence, utilising the knowledge of Production, Work Management and Technical personnel.
How
305.02.04.140. Action Catalogued Materials Return Requirements

Step What Detail The goal of this process step is to determine what Catalogued Materials returns are required due to work undertaken, including the return of unused Materials, Repairable Spares and Service Exchange Items. Return requirements are to be met to ensure that the Materials will be accepted at the store.
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How
To obtain information with respect to materials, open the Work Order on which the Materials were withdrawn or purchased using transaction Change Work Order. The Work Order Operation in the Work Pack also contains information in regards to the Materials that are required to return to the store. The material return requirements may be due to the return of Damaged Repairable Spares, Service Exchange Items, Repairable Spares which have gone through the internal repair process or unused Catalogued Materials. To facilitate the return of Materials to the store, the following is required: for unused Catalogued Materials with an Item Category of 'L', a negative Reservation is required to be created on the original Work Order on which the material was originally issued. If an unused material has the Batch field populated in the original Reservation, the Batch field on the negative Reservation for return is required to match that Batch field. for Damaged Repairable Spares and Service Exchange Items, a negative Reservation will have been automatically created by the system for the return when the component was reserved. This will be visible on the Work Order Operation from the Work Pack. If the Repairable Spare or Service Exchange Item is recommended to be scrapped, or no Repairable Spare or Service Exchange Item is available for return to Store (e.g. totally destroyed in failure), any pieces available are still required to be returned to the Store for acquittal of the Repairable Spares process and to instigate the purchase of a new Material into inventory, ensure the 'Batch' field is left set to DAMAGED. Where there is no item to return, direct contact with Supply is required to ensure the acquittal process in initiated. Repairable Spares which have gone through the internal repair process (either determined as having been repaired or determined to be requiring scrapping), the following is required: - completion of the 'Repaired Material Report', this report may be a hard copy report template printed or obtained on repair/certification, or may form part of the Work Pack and printed as a Production Resource / Tool - a technical inspection, prior to return to the Store, is initiated. - after successful inspection, the Material is to be returned to the Store for Supply to execute the relevant transaction for its processing. (If the Repairable Spare should be scrapped it must still be returned to the store for acquittal of the Repairable Spares process) - an unsuccessful repair will need to be assessed on its merits and action taken accordingly. In addition to the system requirement for the return of materials, a physical return of the material, in accordance with Supply requirements, is also required. Material return requirements will be Operation and Material dependant and may consist of the following: Item preparation Packaging Tagging. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.04.160. Record Single Time Confirmation

Step What Detail The goal of this process step is to perform single Time Confirmations for all completed or partially completed Work Order Operations with the Actual Hours spent on the activity by each resource, each shift.
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How
To record time spent executing activities, use transaction 'Individual Time Confirmation'. On the Enter PM Order Confirmation: Initial Screen enter the following: Order - Enter the Work Order Number Oper./Act. Enter the Work Order Operation Number. Select the Enter button. The Enter PM Order Confirmation: Actual Data screen is then displayed. Within this screen consider the following: Time Confirmations can either be Partial Confirmations or Final Confirmations for the Actual Hours associated with the work. all productive time will be Time Confirmed to the Work Order. Any delay incurred, which is related to a specific Work Order Operation, will be Time Confirmed as part of that Work Order Operation where the resource was not redeployed to another activity during the delay. in the event that a Work Order Operation is never to be executed, a zero hour Confirmation is made for that Work Order Operation with the Final Confirmation tick box selected. The Notification Long text is to be populated with the reason for the zero hour Confirmation. All zero hour Confirmations will be monitored. The following fields are required to be populated: Work Center (Enter the Work Center that actually performed the work) Personnel Number Actual Work Final Confirmation tick (Select if Work Order Operation is Complete). Time Confirmations for internal BHP Billiton Work Centers and Long Term Resource Contractor Work Centers are to be entered for each resource, each shift and are performed in the same manner with the following considerations: where required, the Resource Work Center must be changed to that of the Work Center that actually performed the work. (Work Centers that are not Capacity Relevant are not used in the Planning and Scheduling process and must therefore be selected during Time Confirmation). for Time Confirmations on Work Order Operations that have been Scheduled to be performed by a Internal Work Center but the work was actually performed by a Contractor from an existing Long Term Resource Contractor Work Center, the Contractor's Long Term Resource Contractor Work Center will be entered into the Time Confirmation to ensure that the costs are sent from the correct Labour Cost Center. where more than one resource works on a Work Order Operation, although there is a requirement for individual Confirmations to be entered for each resource each shift, the resources need to collaborate and decide who shall enter the Final Confirmation for a completed task. into the 'Actual Work' field, enter the Actual Hours spent on task. Time Confirmations are required for External Resource Service Work Centers (work performed on PMSV (External Services) Work Order Operations), with the following considerations: in the 'Actual Work' field, enter the duration the task, irrespective of the number of resources One Time Confirmation is required per shift; the last Time Confirmation is to include the Final Confirmation tick. In the case that a Work Order Operation is Partially Finished prior to the Work Order being flagged for Reschedule, the Work Order Operation is required to be Finally Confirmed.
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Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
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Name Finished Work Orders not Completed Planned & Scheduled Work Description Compares the number of finished but not completed Work Orders older than threshold, to the number of Finished but not completed Work Orders. Compares the sum of actual hours Time Confirmed on planned and scheduled Work Orders in the period, to the sum of actual hours Time Confirmed on all Work Orders in the period. Compares the number of finished Scheduled Work Orders in period, to the number of Scheduled Work Orders for execution in period. Compares the number of Scheduled Work Order Operations in period that were started inside a 24 hour window of the scheduled start time, to the number of Scheduled Work Order Operations in the period. Compares the number of finished system generated Work Orders in the period within tolerance, to the number of finished system generated Work Orders in the same period. Compares the number of outstanding Notifications and outstanding Work Orders to the number of open Notifications and open Work Orders. Production Forecast Accuracy metric compares the actual receipts from production quantities to the forecasted figures of saleable products (from the SIC forecast snapshot made in the preceding month). Defines the number of Occupational Illnesses that have occurred within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Type 1 Water Input The total volume of Type 1 water which is received by the operational facility, or which has become available from within the operational facility, from surface water, groundwater and third party water sources within the period. Type 1 water is close to drinking water standards. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Greenhouse Gas Emissions Defines the total amount of Greenhouse Gas Emissions produced within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Fatalities Defines the number of fatalities that have occurred within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application.
Adherence to Schedule Finished within the Week Adherence to Schedule Done on the Day
Compliance to Work Plan
Outstanding Work Orders and Notifications Production Forecast Accuracy
Occupational Illnesses
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HSEC Significant Events
Defines the number of Events, within the period, with a potential level 4 or higher impact in one or more of the following Impact Types from the BHP Billiton Severity Table: - Health - Safety - Environment - Social / Cultural - Reputation The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application.
Total Recordable Injury Frequency
Defines the number of Recordable Injuries (Fatality, Lost Time Injury, Restricted Work Injury, Medical Treatment Injury) per million hours worked (exposure hours) within the period. The frequency, normalised by exposure hours, enables direct comparison between businesses and within businesses over time. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application.
Compares the number of unfinished system generated Work Orders that are overdue, to the number of unfinished system generated Work Orders.
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Level 3: 305.02.06. Close Out Work

Close Out takes the Work Order and Notification to completion, this includes closing redundant Work Orders. This is achieved by entering failure history, initiating Subsequent work and initiating Measurement Documents.
Process Components
Figure 1: Process Components Component Review and Process Completed Work Description The purpose of this component is to assess Work Orders required for close out and to ensure all necessary activities are completed. These requirements differ for system generated and non-system generated Work Orders. The purpose of this component is to action Work Order close out requirements and Technically Complete the Work Order.
Close Work

Key Concepts related to Close Out Work process are outlined in this section. Concept Review Completed Corrective Work Description The following requirements are determined when work is finished: - Measurement Document creation required - Counter replacement required - Work Plan restart required - identification and closure of Redundant Work Orders. In order to Technically Complete Work Orders the following checks are required: - correct any costing errors (CSER) - ensure all goods have been receipted - all required Service Entry Sheets have been created - ensure all Purchase Orders are Receipted - Purchase Requisitions without Purchase Orders are closed - Time Confirmations, including Final Confirmations are completed - all Repairable Spares and Service Exchange items have been returned to the store. Note: No more Planned Costs can be added once the Work Order is Technically
Technically Complete Work Order
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Completed. Why is the Close Out Work Process Important to BHP Billiton? This process is triggered when the work activity is completed. For corrective work, impact data is captured to assist in continuous improvement. Subsequent Notifications are initiated for work identified during an inspection. If readings have been taken during a preventive activity, these will be initiated as Measurement Documents. Completed corrective work, is to be reviewed to determine if existing Work Orders are now redundant. If so, the Work Orders will need to be closed with the reason noted on the Notification. The work order is then completed and the work execution history captured during close out is analysed.
Activities
Activity Update Maintenance Engineering Change Notification History Description The objective of this activity is for the learner to update Maintenance Engineering Change Notifications with additional information.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31907?mode=EU Update Investigation Notification History The objective of this activity is for the learner to update Investigation Notifications with additional information.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31903?mode=EU Update Work Request Notification History The objective of this activity is for the learner to update Work Request Notifications with additional information.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31911?mode=EU Assess Close Out Requirements The objective of this activity is for the learner to: - assess the Work Orders requiring close out - create a Subsequent Notification from the originating Notification.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31212?mode=EU Update Event Notification History The objective of this activity is for the learner to update Event Notifications with additional information.
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Component : Review and Process Completed Work 305.02.06.010. Assess Close Out Requirements
Step What Detail The goal of this process step is to assess the Work Orders requiring close out and ensure all necessary activities are completed. The required actions for system generated and non-system generated Work Orders may differ. To assess close out requirements, use transaction Change Work Orders (Selection List) and complete only the following fields: In Process - Select Main work center Enter the Main Work Center Planning Plant Enter the Planning Plant Basic Start Date to Enter the end of current Schedule Period. Execute Transaction, select and open individual Work Order to assess (Click 'Details' button). Use of written comments on the Work Packs (Work Order Form including attachments) may also be utilised. Initiate the following where relevant: Creation of a Subsequent Notification for an activity identified from a post work evaluation activity or for work on the same Technical Object (excluding from PM04 Work Orders). where the Work Order was for the execution of an Investigation, review the originating Investigation Notification and raise a Subsequent Notification for each corrective action described in the Notification Long Text. Creation of Master Data Management (MDM) Request for the change of the Functional Location Characteristics due to the installation or removal of a Linear Object within a Functional Location. Inform the responsible Planner Controller of the requirement to initiate a restarting of a Work Plan due to the replacement or overhaul of equipment or components occurring out of cycle with the associated Work Strategies where the Work Order was for the execution of an Investigation determine External Investigation Reporting requirements. All Events that have previously been reported to External Stakeholders will most likely require external reporting of the Investigation outcomes. to identify if the originating Event has been previously reported to external stakeholders perform the following: - Access the Event Notification (prior Notification to the Investigation Notification) by accessing the 'Event / Work Details' tab, then double mouse Clicking on the Notification number listed in the 'Prior Notification' field - the prior Event Notification is then displayed in display mode - Access the 'Documents & Investigation Findings' tab to review the Controlled documents attached to the Notification. If External Event Reporting has been previously performed evidence of this reporting will be attached in the 'Linked Documents' sub screen. - to return to the Investigation Notification Click on the 'back' button. consult the External Reporting Protocol and any relevant business stakeholders for guidance. Where external investigation reporting is required communicate to the person responsible for External Reporting that the Investigation information is ready for External Reporting. review all Work Order Operations to confirm work has been executed as required and identify execution History Requirements, including: - Work Order Execution History comments has been captured in the Notification
How
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Long Text where required - supporting documentation has been attached via the General Object for Services or as a Document Information Record where required where the Work Order was triggered by an Event Notification, review the Event Notification and ensure all requirements have been met. Investigation Execution Work Where the Work Order was for the execution of an Investigation, confirm the following on the originating Investigation Notification: a Timeline Chart and 5 Why Analysis and has been attached as either a controlled or uncontrolled document investigation Findings have been entered into the Notification Findings tab. This includes categorisation of findings into root cause categories with supporting Short Text / Long Text descriptions for all investigated Events where external reporting was performed, that evidence of all communications is attached as a Document Information Record the Investigation Evaluator has provided an update in the Notification Long Text that they have reviewed and approved the Investigation. Engineering Change Assessment Work Where the Work Order was for the execution of an Engineering Change Assessment, confirm the following on the originating Engineering Change Notification: an Approved Engineering Change Risk Assessment has been attached to the Notification as either a Controlled or Uncontrolled Document - Review the Risk Assessment and conform the risks associated with the Engineering Change have been adequately identified, assessed and controlled - based on level of the risk assessment (low, moderate, high, extreme), the approval may be escalated to higher level management. Team decision meeting could be arranged by including all stakeholders. any additional Assessments have been attached as either a Controlled or Uncontrolled Document and any additional work from these assessments defined in the Notification Long Text all Corrective / Preventive Actions (Risk Mitigation Plan) identified in the Risk Assessment have been adequately defined in the Notification Long Text including: Name of Person to perform the work, Start Date / Finish Date, Estimated Work Effort Duration (in hours) and specific description of the work required all Work required to implement the Engineering Change has been adequately described in the Notification Long Text. If the Engineering Change Assessment has met all of the above requirements, evaluate the completed Engineering Change Notification and perform one of the following: if the Engineering change proposal is not approved, record the reasons for rejection in the Notification Long Text and proceed to close out of the Notification and Work Order if the Engineering change proposal is approved, this fact is to be recorded in the Notification Long Text: - proceed to create a Subsequent Work Request Notification for each Corrective / Preventive Action and identified work requirement to implement the Engineering Change described in the Long Text.
Safety Critical Element (SCE) Work When replacing a Certified Material, physically installed in the Safety Critical Element, the following actions are relevant: the responsible Planner Controller is to be informed of the requirement for a Master Data Request to be initiated to update the Recertification Date on the Characteristic of the Safety Critical Element to that of the required future Recertification Date the responsible Planner Controller is to be informed of the requirement to initiate the
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restart of the Recertification Plan to reflect the Recertification Date stipulated by an inspector and align with the Operation Production Plan. where history is required to be recorded for work performed on a system-generated Work Order, a Notification will be required to be created 1:1 with the Safety Critical Element; this may require multiple Notifications to be created where there are multiple Safety Critical Elements in the Object List. When there is a requirement to create a Notification for an Object in the Work Order Object List, consider the following: - any work executed within a Work Order, as outlined on a Work Instruction or Work Order Operation, will be recorded in a Notification assigned to that Work Order, which may also require the creation of additional Notifications against the Object List. The Notifications for this history will be 'Work Request' Notifications as the work executed is as a result of work that was requested to be executed in the Work Instruction or Work Order Operation - any work that was not to accomplish the intent of the Work Order will have been created as a Subsequent Notification or new Notification, which will then go through the normal approvals process. To create a Work Request Notification for an Object in the Object List perform the following: in the line in which the Object is listed, select the Create Notif. button (white paper button, which is located in the Navigation column). The Notification Type pop-up screen will then be displayed with Notification type already defaulted. Click the Continue (Enter)' button. A New Notification will then be created enter required initial information on Notification and ensure the following: - Coding - PM00022, Work Request - Priority 3 P: Planning to record History on the Notification, proceed to the Update History process step. Refurbishment Work The history for a Refurbishment Work Order is recorded in a Document Information Record referencing the Material number and serial number in the Characteristics, therefore history is not recorded on a Notification. Non-System Generated Work As a result of the work performed, the responsible Planner Controller is to be informed of the requirement to perform the following: replacement of a Counter - Where a physical Counter has been replaced, a Measurement Document is required to be created to ensure that the Work Orders call in line with the Work Strategy. System Generated Work Proceed to update the Notification to capture History on a system-generated Work Order (Where a system-generated Work Order has been completed with no additional activities completed and no requirement to log history, there is no requirement to update the Notification). Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.06.020. Initiate Subsequent Notification

Step What Detail The goal of this process step is to create a Subsequent Notification from the originating Notification. Subsequent Notifications must comply with granularity rules.
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How
To create a Subsequent Notification perform the following: continue within the current transaction access the originating Notification by Clicking the 'Change' button (pencil button located to the right of the Notification number) within the originating Notification Click the 'Subsequent Notification' button located on the 'Impact Data' tab. Upon selection a new Notification will be created and the 'Prior Notification' field on the 'Event/Work Details' tab will be populated with the originating Notification. When creating Subsequent Work Requests ensure the following requirements are met: if creating Subsequent Work Requests for Corrective Actions defined in the Long Text of Notifications each Corrective Action must be created as one independent Work Request the Work Request complies with granularity rules (Referenced in the Schedule Management Design Intent). Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.06.050. Update General Notification History

Step What Detail The goal of this process step is to update Notifications with additional information. Within this process step the following is updated on the Notification: Controlled and Uncontrolled Documents, where required Executed Work Order Operation History, where required. To update Notification history perform the following: locate the Notification by performing one of the following: - if currently within a Work Order Click the 'Change' button (pencil button located to the right of the Notification number) or by selecting the appropriate Notification from the Object list - if accessing a Notification with a known number, use tr ansaction Change Notification, enter the Notification number in the Notification field and execute the transaction - if accessing a Notification with a known Work Order number, use transaction 'Change Notification', Click the 'Notification' field, the 'Possible Entries Search' button will be displayed, Click the button to bring up the 'Display Notifications: Selection of Notifications' screen, if this is not displayed, Click back and select 'PM notifications by notification list' to bring up the selection. Use the selection 'Display Notifications: Selection of Notifications' and in the 'Order' field enter the Work Order number, Click 'Execute' button, the Notification number is populated in the 'Notification' field. For history to be recorded for work performed on items in the Work Order Object List, follow the same steps as above. If the Notification has been assigned a System Status of Completed (NOCO), put the Notification In Process (NOPR) by performing the following only: Click In process again button Click 'Continue when status check warning dialog box appears. Notification is then saved with the 'In Process' (NOPR) System Status. the 'Change Notifications' screen is again displayed with the Notification number already pre-populated in the Notification field, Click 'Enter'. Update the following information on the Notification where required:
How
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Record Work Order Operation History Where executed Work Order Operation History Capture is required perform the following: enter history information into the Notification Long Text which provides a detailed description on the work activities performed where required, attach evidence of work execution to the Notification as either a Controlled Document or Uncontrolled document using the process outlined below. Uncontrolled Document Should any uncontrolled document be available to support the Notification (e.g. photo, sketch, report), this may be attached to the General Object for Services on the Notification as a PDF document using the function 'Store Business Document'. To attach the uncontrolled document into the Notification perform the following: Click the 'Services for Object' arrow button Navigate to Create > Store business document, the 'Archive from FrontEnd' screen displays Double Click '1SAP: Plant Maintenance Notification' and browse the file from local drive Select the file and Click 'Open' button, then Click 'Continue' button Enter a note in the Notification Long Text regarding the relevance of the attachment. Controlled Document Should any Controlled Document be available to support the Notification perform the following: for Controlled Documents that have been created as a 1SAP Document Information Record. Select the 'Documents & Investigation Findings' Tab, scroll down to the Linked Documents sub screen and perform the following: - Ty. PMA - Document Enter the Document Information Record number, if unknown perform the following: - in the Document field Click the Possible Entries Search button, the search functionality box is displayed - from the popup box select 'Find document via class' - in the 'Find Objects in Classes' screen complete the following fields: - Class - DM_PMAC_COMM (Document Info record Common) - Class Type 017 (Document management) - Click 'Continue (Enter)' button, in the search screen enter the relevant Document Information Record Characteristic values (e.g. Maintenance Planning Plant, Main Work Center) - Click 'Find in initial class' button, a list of Object (Document Number) is generated - Click 'Change Layout' button (button to the right of green tick) to bring other Characteristic value into the list if necessary (e.g. Description) - if further detail is required on the Document Information Record, highlight the line item and Click 'Display Document Info Record' button (arrow button next to Clock button) and choose 'Display document' to display the Document Information Record Master Data. To return to the list Click 'Back' button - in the 'Find Objects in Classes' screen highlight the desired line item (Object) and Click 'Copy' button, the document number is copied over to Linked Documents sub screen. Click the Enter button to allow details to be updated. For Controlled Documents that have not been created as a 1SAP Document Information Record, proceed to the creation of the Document Information Record. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
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305.02.06.051. Update Event Notification History

Step What Detail The goal of this process step is to update the Event Notifications with additional information. Within this process step the following is updated on the Notification: Originating Event information, where required Impact Data (e.g. Failure data) where required. To update the Event Notification with additional information update the following areas of the Notification where required: Event / Work Details Tab: Notification Date / Time - For Events only update if the investigation identified a different Event occurred date and time than is currently recorded on the Notification Impact Data Tab: An Item is required to be created for each Impact associated with an Event (e.g. Safety Impact, Financial Impact). Review the Risk Management Group Level Document Severity Table to determine the Impact Type and the total number of Impacts for the Event. For each Impact perform the following: on the Item sub screen Click in the 'Impact Type' blank field, the 'Possible Entries Search' button will then be displayed, Click the button and on the pop-up menu the list of Impact Types will be displayed. Select the relevant Impact type and Click 'Choose' button. Damage: - damage information must only be completed for Events where Impact Type = Financial and damage to property or equipment has also resulted - from the catalogue select the category which best represents the damage to the object and Click 'Choose' button. Item Text: - Item Text must be completed in line with the following requirements: - for Events where Impact Type = Financial and damage to equipment has also been a result, enter a description of the specific Object Part Impacted or Damaged - for Events where Impact Type = Safety, enter additional information on the Injury (e.g. Injury Classification). - Long Text may be added to compliment Short Text where required. Cause Code: - Cause Code information must only be completed for Events where Impact Type = Financial and damage to property or equipment has resulted - from the catalogue select the category which best represents the cause of damage to the object. Cause Text: - Cause Text must only be completed for Events where Impact Type = Financial and damage to property / equipment has also been a result - provide supporting free text information on the cause of the damage. The short text field has a 40 character limit so the long text field may also be used. Item Details: - additional details are required for each defined Impact (Notification Item). To enter Item details perform the following: - Select Item Details (middle button of the 3 vertical buttons in the right hand side of the Item area) - on the Item Details popup screen select the Class: PM_NOTI_E' button. The Item Classification screen will then be displayed. Item Classification:
How
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- on the Item Classification screen all of the following must be completed: - Severity Level Actual Consult the Risk Management Group Level Document Severity Table to determine the Actual Severity rating of the Event. Click in the Severity Level Actual blank field, the 'Possible Entries Search' button will then be displayed, Click the button and on the pop-up menu the list of Severity Level Actual will be displayed, select the Actual Severity Level of the Impact Type and Click Continue button. - where the Impact Type = Safety and the Actual Severity Rating = 3 (to represent a Restricted Work Case or Lost Time Case) a completed Recordable Injury Classification form must be attached to the Notification either as a Controlled or Uncontrolled Document. - Severity Level Potential Consult the Risk Management Group Level Document Severity Table to determine the Potential Severity rating of the Event. Click in the Severity Level Potential blank field, the 'Possible Entries Search' button will then be displayed, Click the button and on the pop-up menu the list of Severity Level Potential will be displayed, select the Potential Severity Level of the Impact Type and Click Continue button. - Control Level From the catalogue select the HSEC Control level of the Event. - Vendor Where an employee of a Vendor (contracted organisation) is either the main person involved in the Event or the person injured or suffering an illness the Vendor must be selected against all Event Safety and Health Impacts (Notification Items). To select a Vendor perform the following: - Click in the 'Vendor' blank field, the Possible Entries Search button will then be displayed, Click the button and on the pop-up menu the Vendor Search fields will be displayed. - within the pop-up screen, Click on the 'Input Help Selection List' button (located near the top right hand corner, situated to the right of the right arrow button. - from the drop down list select 'Vendors: Purchasing'. - on the updated pop-up screen enter one of the following: - Name - Name of the Vendor if known. Consider the use of the wildcard assist search - Vendor - Enter Vendor number if known - Purch Organization - Click the 'Possible Entries Search' button, and from the list select the relevant Purchasing Organisation. - Click the 'Start Search' button (green tick at bottom right) - From the returned list of results, Click the relevant Vendor (if there is more than one of the same Vendor ensure it is assigned to the correct Purchasing Group to select the appropriate Vendor) and then Click the 'Copy' button (green tick at top left), then Vendor details are recorded into the 'Vendor' field. Click the 'Enter' button to complete. - to return to the Impact Data Tab, Click the 'back' button (green arrow button at top of screen) on the popup screen Click 'Close' button (green tick).
Where an additional item is required to be created due to the Event resulting in multiple impacts, create a new item by performing the following: Click the Create Item button (top button of the 3 vertical icons in the right hand side of the Item area) Repeat the process for item data entry as described above For existing Items review and update the following where required: Impact Type Damage Text Cause Code Cause Text Item Characteristics: - for existing Item Characteristics review and update the following where required: - Actual Severity Rating
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- Potential Severity Rating - Control Level - Vendor Where Impact Data on a non-investigated Event has been updated from that originally entered during Notification population, proceed to reassess Investigation requirements. Controlled Document The following documentation must be attached to the Event Notification as a Document Information Record (Controlled Document): all External Stakeholder Event Reports all evidence of External Stakeholder Event Reporting all documentation that according to business requirements must remain private and confidential for a Notification where Impact Type = Safety, and Actual Severity = 3, attach the Recordable Injury Classification Form. To Complete Notification History Update, perform one of the following: for Notifications which were reopened for update, complete the Notification by Clicking the Complete button (finish flag) for Notifications which were accessed from a Work Order, return to the Work Order by Clicking the 'Change' button (pencil button located to the right of the Work Order Number) for all other Notifications, save and exit the Notification.
305.02.06.052. Update Work Request Notification History

Step What Detail The goal of this process step is to update the Work Request Notification with additional information. To update the Work Request Notification with additional information enter the additional information into the required Notification fields and tabs. To Complete Notification History Update, perform one of the following: for Notifications which were reopened for update, complete the Notification by Clicking the Complete button (finish flag) for Notifications which were accessed from a Work Order, return to the Work Order by Clicking the 'Change' button (pencil button located to the right of the Work Order Number) for all other Notifications, save and exit the Notification.
How
305.02.06.053. Update Investigation Notification History

Step Detail
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What
The goal of this process step is to update the Investigation Notification with additional information. Within this process step the following is updated on the Notification: Investigation Findings Corrective and Preventive actions Investigation Documentation. To update the Investigation Notification update the following information on the Notification where required: Event / Work Details Tab: Long Text - if updating Notification History with corrective and preventative actions perform the following: - if the investigation actions are not described in a document that can be attached to the Notification, the long text must be updated with a description of all corrective actions identified by the investigation including: - a description of the specific action - Name of Person the action is to be assigned to - Start date, Finish date, and approximate Work Effort (in hours) of the action - where required, a description of any further information / documentation that can be used to support the execution of the action once it has been translated into a Work Order Operation - if the investigation actions are described (in detail that meets the above requirements) in a document that can be attached to the Notification, attach the document to the Notification (in line with controlled document requirements) and reference the document attachment within the Notification Long Text. - if updating Investigation Notification following Investigation Evaluation indicate in the Long Text with a comment that the Investigation was successfully evaluated. Documents & Investigation Findings Tab: Investigation Findings must be recorded for all Investigation Notifications in the Documents & Investigation Findings tab. To record an Investigation Finding scroll down to the Activities sub screen and perform all of the following: Click in the 'Code group' blank field, the 'Possible Entries Search' button will become visible Click the 'Possible Entries Search' button from the displayed menu select a category that best represents the Investigation Finding root cause category. To obtain additional information on the categorisation Click the 'Display Long Text' icon to the right of category name. Select the relevant Category from the list and then Click the 'Choose' button at bottom, the 'Code group' and 'Activity code text' fields will be populated Enter Activity Text by performing the following: Enter a short description of the Investigation finding that supports the Code Group selected. Where required enter Long Text by performing the following: once Activity text has been entered, hit Enter Click 'Create text' icon (to the right of Activity text field) on the Long Text screen enter a long text description of the Investigation Finding that supports the Short Text and Code Group selected. Repeat the process until all Investigation Findings have been entered Investigation Documentation: Attach all relevant Investigation documentation as either a Controlled or Uncontrolled Document. The Timeline Chart and 5 Why Analysis must be attached to the Notification
How
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Controlled Document The following documentation must be attached to the Notification as a Document Information Record (Controlled Document): all documentation for an Investigation that is under Legal Professional Privilege all evidence of External Stakeholder Investigation Reporting all documentation that according to business requirements must remain private and confidential To Complete Notification History Update, perform one of the following: for Notifications which were reopened for update, complete the Notification by Clicking the Complete button (finish flag) for Notifications which were accessed from a Work Order, return to the Work Order by Clicking the 'Change' button (pencil button located to the right of the Work Order Number) for all other Notifications, save and exit the Notification. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.02.06.054. Update Engineering Change History

Step What Detail The goal of this process step is to update the Engineering Change Notification with additional information. Within this process step the following is updated on the Notification: Engineering Change Risk Assessment Corrective and Preventive actions Additional Assessments (where required). To Update the Engineering Change Notification with additional information the following information is required: Approved Engineering Change Risk Assessment attached to the Notification as either a Controlled or Uncontrolled Document. Corrective / Preventive Actions (Engineering Risk Mitigation Activities) listed in the Notification Long Text with the following detail for each action: - name of person to execute the Work, if known - Start Date and Finish Date for the Work, if known - Estimated Work Effort Duration (in hours) - clear Detail on the Work that is required. where required additional Assessments attached as either Controlled or Uncontrolled Documents, and associated follow up actions clearly defined in the Notification Long Text in accordance with requirements listed above description of all additional work required to implement the Engineering Change clearly defined in the Notification Long Text in accordance with the requirements listed above. To Complete Notification History Update, perform one of the following: for Notifications which were reopened for update, complete the Notification by Clicking the Complete button (finish flag). for Notifications which were accessed from a Work Order, return to the Work Order by Clicking the 'Change' button (pencil button located to the right of the Work Order Number) for all other Notifications, save and exit the Notification.
How
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Name Compliance to Work Plan Description Compares the number of finished system generated Work Orders in the period within tolerance, to the number of finished system generated Work Orders in the same period. Compares the number of finished but not completed Work Orders older than threshold, to the number of Finished but not completed Work Orders. Compares the number of outstanding Notifications and outstanding Work Orders to the number of open Notifications and open Work Orders.
Finished Work Orders not Completed Outstanding Work Orders and Notifications
Immediate/Urgent Work Orders Compares the number of Notifications for Immediate/Urgent Work Orders with Impact Data Entered completed in period with all three Impact Data Codes entered, to the number of Notifications for Immediate/Urgent Work Orders completed within period. Production Forecast Accuracy Production Forecast Accuracy metric compares the actual receipts from production quantities to the forecasted figures of saleable products (from the SIC forecast snapshot made in the preceding month). Defines the number of fatalities that have occurred within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. HSEC Significant Events Defines the number of Events, within the period, with a potential level 4 or higher impact in one or more of the following Impact Types from the BHP Billiton Severity Table: - Health - Safety - Environment - Social / Cultural - Reputation The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Total Recordable Injury Frequency Defines the number of Recordable Injuries (Fatality, Lost Time Injury, Restricted Work Injury, Medical Treatment Injury) per million hours worked (exposure hours) within the period. The frequency, normalised by exposure hours, enables direct comparison between businesses and within businesses over time. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Cancelled System Generated Work Orders Compares the number of system generated Work Orders cancelled in period, to the number of system generated Work Orders completed in period. Compares the number of unfinished system generated Work Orders that are
Fatalities
Overdue System Generated
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Work Orders
overdue, to the number of unfinished system generated Work Orders.
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Level 2: 305.03. Shutdown Management

Utilised to apply a higher level of control over the increased risk introduced in the form of safety, including opportunity to comply with low frequency statutory obligations, condensed volume of work, higher complexity and interaction of work, compressed timeframe and increased cost commitment. The establishment of the Shutdown sets the framework for scope of work development, optimisation of resources, duration and cost and mobilisation activities. Interdependencies with Inventory, Procurement and Contractor Management enable resources to be available as scheduled. Execution of Shutdown work is controlled to identify and act on deviations to schedule or cost.
Level 3 Processes

Key Concepts related to Shutdown Management process are outlined in this section. Concept Description
Why is the Shutdown The Shutdown Management main process is important because it; Management Process - controls the higher level of risk introduced in the form of safety, including the Important to BHP Billiton? opportunity to comply with low frequency statutory obligations - enables the execution of a successful shutdown by monitoring the completion of planning and optimising activities as part of shutdown mobilisation - optimises resources, costs, and the duration of the shutdown - enables the approval of any alterations to the shutdown scope - controls the execution of the shutdown allowing corrective action to be taken for unforeseen events. Overview: Establish Shutdown The framework under which the preparation for the Shutdown will occur. Confirms that the long term Shutdown forecasts are valid and Revision numbers exist. Resources are allocated to the Shutdown to enable planning, optimisation, mobilisation and execution. Scope of work is determined based on work priority, critical path and allocated budget. Pre-work is identified for execution. Task Lists are identified for creation and assigned to Work Orders, building a repository for repeatable tasks.
Overview: Develop Work Scopes
Overview: Approve Scope A scope of work is determined based on work priority, critical path contribution of Work and allocated budget. Scope is approved and the work is validated as fully understood. Work Orders are released triggering inventory, procurement and optimisation.
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Overview: Optimise Shutdown Overview: Authorise Scope Amendment
Takes the detailed Scope of Work and optimises the cost, duration and resources required to execute the shutdown. A fully resourced schedule (with baseline) is validated prior to handover for execution. Business impact, duration of shutdown, cost and resource availability is considered prior to approving a Scope of Work alteration. Project status provides visibility for the inclusion and removal of work, providing the basis for reporting and auditing shutdown activities. Effective mobilisation ensures the organisation is prepared for the shutdown and includes: - pre-start meetings - implementing Risk Assessment controls - mobilisation of people and services - verification of material and consumable availability. Execution commences when peak production has stopped and execution concludes when commissioning is completed. Execution is controlled by the shutdown schedule. Control over the execution includes monitoring of (including acting on) deviations from schedule or cost. The Close Out Shutdown process commences with a close out meeting that analyses the performance of the shutdown and relevant historical information relating to the shutdown is captured in a report. Work history is captured in Notifications for future analysis.
Overview: Mobilise Shutdown
Overview: Execute and Control Shutdown
Overview: Close Out Shutdown
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Level 3: 305.03.05. Authorise Scope Amendment

Business impact, duration of Shutdown, cost and resource availability is considered prior to approving a Scope of Work alteration. Project status provides visibility for the inclusion and removal of Work Order Shutdown work.
Process Components
Figure 1: Process Components Component Initiate Scope Amendment Description The purpose of this component is to explain how to initiate amendments to the approved work scope. The purpose of this component is to explain the process of assessing amendments to the scope. The purpose of this component is to explain the process for approving amendments to the scope. The purpose of this component is to explain how to integrate approved scope amendment.
Assess Scope Amendment
Approve Scope Amendment
Integrate Approved Scope Amendment

Key Concepts related to Authorise Scope Amendment process are outlined in this section. Concept Why is the Authorise Scope Amendment Process Important to BHP Billiton? Description The Authorise Scope Amendment occurs when the shutdown Scope of Work requires amendment from original approved shutdown scope. The business impact of an identified requirement for the alteration of the approved Scope of Work is assessed based on schedule (Critical Path), budget, HSEC and Equipment integrity. The alteration to the approved Scope of Work is approved or rejected and the schedule is updated, where appropriate. This is followed by the continuation of shutdown activities. Any change after scope approval requires the Scope Amendment process to be followed.
Component : Initiate Scope Amendment 305.03.05.010. Complete Scope Amendment Request
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Step What
Detail The goal of this process step is to formalise requests for amendments to the Approved Scope of Work, allowing for subsequent assessment and approval based on the business justification for the change. The Scope Amendment Request is a manual form to accommodate expediency in off-line processing during Shutdown execution. If not Approved, the record can prompt for a Notification to be raised post Shutdown to address the potential failure at a future date. Approved requests can be analysed to detect possible opportunities for improvement by identifying the scope requirement earlier in future Shutdown events.
How
To complete a Scope Amendment Request, populate the required fields on a blank form. Make it clear if the request is for the addition or removal of Work Orders. If possible, pre-empt which lower Priority work will be removed to accommodate the requirements of emergent work. At this stage, focus on the business justification supported by known or estimated impacts to the Shutdown cost, duration or resources. If this information is not complete, the amendment request will not be Approved at the rationale challenge stage.
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Name Outstanding Work Orders and Notifications Planned & Scheduled Work Description Compares the number of outstanding Notifications and outstanding Work Orders to the number of open Notifications and open Work Orders. Compares the sum of actual hours Time Confirmed on planned and scheduled Work Orders in the period, to the sum of actual hours Time Confirmed on all Work Orders in the period. Compares the number of unfinished system generated Work Orders that are overdue, to the number of unfinished system generated Work Orders.
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Level 3: 305.03.07. Execute and Control Shutdown

Execution commences when peak production stops and execution concludes when commissioning is completed. Execution is controlled by the Shutdown schedule. Control over the execution provides monitoring for and acts on deviations from schedule or cost.
Process Components
Figure 1: Process Components Component Prepare for Shutdown Execution Description The purpose of this component is to describe the steps involved to complete preparation activities for shutdown execution.
Execute and Control Shutdown The purpose of this component is to explain the controls and measures in Work place for shutdown execution.

Key Concepts related to Execute and Control Shutdown process are outlined in this section. Concept Why is the Execute and Control Shutdown Process Important to BHP Billiton? Description The process Execute and Control Shutdown is started once the shutdown event has been mobilised. Work requirements are communicated and task preparation activities are completed. Work is executed as per the Shutdown Schedule. Shutdown progress is monitored and status updated. On completion, equipment is handed back to Production. Once the shutdown execution is complete, demobilise the site and analyse the event.
Component : Prepare for Shutdown Execution 305.03.07.030. Issue / Handover any Permit Requirements
Step What Detail The goal of this process step is to have all required permits in place and current, prior to the commencement of a task, thereby controlling identified hazards.
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How
To issue or handover permits, refer to the procedures in the Shutdown HSEC plan and Operation requirements. Approvals for required permits and certificates are prepared and reviewed, ensuring all Operation HSEC requirement are satisfied (e.g. signage, gas testing, barricading, isolation, PPE and fire fighting equipment). Where a task is ongoing between shifts, complete permit handovers and any required condition recertification.
305.03.07.040. Execute Plant Ramp Down Activities

Step What Detail The goal of this process step is to transition the plant and equipment from an operating state to one which is safe for Shutdown execution. Once plant and equipment are prepared for safe access, proceed with system and process level isolations according to the Shutdown HSEC plan. How To execute plant ramp down activities, execute tasks as nominated on the Shutdown Schedule. To complete equipment handover, Fatal Risk Controls Group Level Document and Operation requirements must be complied with, this may include: Completing handover checklists Obtaining appropriate permits to work. Where approved in the Shutdown project plan, execute the requirements of any block isolations.
305.03.07.050. Complete Isolation and Local Hazard Requirements

Step What Detail The goal of this process step is, prior to the commencement of work each shift to: - have all isolations in place, thereby providing a safe work environment - identify and mitigate any on the day hazards associated with the work environment or interactions with other tasks. To complete isolation and local hazard identification, refer to the procedures in the Shutdown HSEC plan and local Operation requirements. Prior to signing (lock / tag) onto any system or process level isolations, understand which equipment is included and its relevance to assigned task. Identify any further localised isolation that may be required to provide a safe working environment. Localised hazard assessments are to consider environmental conditions that exist on the day, for example, hazardous working area induced by weather or work undertaken on the prior shift or commencement of other tasks within the work environment. Complete any required mitigating actions prior to the commencement of work or escalate irresolvable conditions as per the Shutdown HSEC and communication plans.
How
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305.03.07.060. Execute Work as per Shutdown Schedule

Step What Detail The goal of this process step is to execute the Shutdown in accordance with the current Shutdown Schedule. To execute the work, the Work Packs (Work Order Form including attachments) are referred to, to determine the full scope of the activity. Particular attention is paid to the safety considerations of the task, including ongoing permit testing requirements. During the work execution, if any requirements arise that are additional to the tasks being performed, the Supervisor is to be notified before proceeding. Work identified within the original scope may be performed on current Work Order Operations. Work deemed to be not within the original scope will require the initiation of a Shutdown Scope Amendment Request. Complete quality assurance and inspection and test hold points as nominated. To prepare the site for shift end, the work area and equipment is to be left in a safe and secure state by considering: * Work area housekeeping, (e.g. routing leads, removal of rubbish) * Temporary accesses are accessible * Minimisation of work area obstructions * Out of service tags are placed on equipment with outstanding work requirements.
How
305.03.07.100. Finalise Work Area Activities

Step What Detail The goal of this process step is to leave the Work Area in a safe, and ready for commissioning state prior to the commencement of further work. Further, by updating the supervisor of task completion, accurate assessment of progress can be made and continuity of work can be maintained. Updated Work Orders and attachments are returned to the Shutdown control room. To finalise work area activities, prior to the commencement of further work: - verify quality assurance, inspection and test requirements are completed - undertake work area housekeeping - remove any personal danger tag and de-isolate equipment - close (sign off) any task specific permits - record required information on the Work Order and attachments - note any continuous improvement information on the Work Order Once completed, notify the work Supervisor of task completion and return all documentation to the Shutdown control room. Note any outstanding demobilisation items in the Demobilisation Plan.
How
305.03.07.110. Execute Plant Commissioning and Ramp Up Activities

Step What Detail The goal of this process step is to transition the plant and equipment from Shutdown execution to pre Shutdown production levels, ensuring plant and equipment is in a safe to operate state by verifying integrity of operating equipment (e.g. leaks) and
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reinstatement of safety protections (e.g. interlocks). How To commence Plant Commissioning and Ramp Up Activities, where established de-isolate and finalise outstanding permit requirements, including block isolations, as per the procedures in the Shutdown HSEC plan and Operation requirements. To complete system and process commissioning, execute activities as nominated on the Commissioning Plan. Individual equipment commissioning may form part of the Work Order inspection and test plan. The commissioning plan for a system or process will be predetermined during the mobilisation phase and must be executed in full, irrespective of Work Scope executed. Obtain authorisations (signatures) as called for in the Commissioning Plan. To complete equipment handover, Fatal Risk Controls GLD and Operation requirements must be complied with, this may include: * Completing handover checklists Execute plant ramp up activities tasks as nominated on the Shutdown Schedule. Upon reaching peak production, continue to monitor equipment maintained (or installed) during the Shutdown under full operating load.
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Name Production Forecast Accuracy Description Production Forecast Accuracy metric compares the actual receipts from production quantities to the forecasted figures of saleable products (from the SIC forecast snapshot made in the preceding month). Compares the number of outstanding Notifications and outstanding Work Orders to the number of open Notifications and open Work Orders. Compares the number of finished system generated Work Orders in the period within tolerance, to the number of finished system generated Work Orders in the same period. Compares the sum of actual hours Time Confirmed on planned and scheduled Work Orders in the period, to the sum of actual hours Time Confirmed on all Work Orders in the period. Compares the number of unfinished system generated Work Orders that are overdue, to the number of unfinished system generated Work Orders.
Outstanding Work Orders and Notifications Compliance to Work Plan
Planned & Scheduled Work
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Level 2: 305.05. Data Management

Collection of processes to manage Batch Jobs, housekeep Transactional Data and verify underlying Master Data is correct.
Level 3 Processes

Key Concepts related to Data Management process are outlined in this section. Concept Description
Why is the Data The Data Management process is important because it encompasses the Management Process following activities: Important to BHP Billiton? - Maintaining Work Plans and Measurement Documents - Monitoring of batch jobs - Cost Settlement and Business Completion of Work Orders - the review and rectification of errors in Work Orders - the review and rectification of errors in Time Confirmations. Overview: Maintain Plans The Maintain Work Plans and Measurement Documents process includes the & Measurement following activities: Documents - creation of Measurement Documents from readings taken automatically, during an inspection or routine counter collection - execution of the Deadline Monitoring batch job - scheduling of new and modified Work Plans. Overview: Maintain Data Quality The Maintain Data Quality process includes the following activities: - reviewing Work Plan Deadline Monitoring errors - reviewing annual counter estimates - reviewing planned Activity Rates on Work Centers - rectifying Work Order closure issues - inspecting Material repairs - locating defective materials - reprocessing and cancelling Time Confirmations - rectifying Measurement Documents - uploading Activity spreadsheets for Finance. The Settle and Complete Work Orders process settles Work Orders and identifies Work Orders with settlement errors. The errors are an output after the batch job run. The Work Order settlement batch job is run daily and Work Orders with settlement errors are output to the settlement error log.
Overview: Settle & Complete Work Orders
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Level 3: 305.05.01. Maintain Plans and Measurement Documents

Includes the creation of Measurement Documents triggered from readings taken during an inspection or routine counter collection and execution of the Deadline Monitoring Batch Job. New and modified Work Plans will require scheduling. The outcome is the creation of Notifications and Work Orders to support the underlying Work Strategy.
Process Components
Figure 1: Process Components Component Maintain Work Plans Description The purpose of this component is to provide an overview of maintaining Work Plans and reviewing the Deadline Monitoring batch job.
Create Measurement Readings The purpose of this component is to provide an overview for the creation of the various measurement readings.

Key Concepts related to Maintain Plans and Measurement Documents process are outlined in this section. Concept Start/Restart Work Plan Create Measurement Document Description When restarting Work Plans, the start date of the cycle must be back-dated to reflect either the actual or theoretical date of last completion. In line with the defined Work Strategy, there is a requirement to enter a Measurement Document against a Measuring Point to enter the required readings. These readings influence Work Plan call schedules and the generation of Condition Based Notifications.
Create Measurement Doc Measurement Documents are recorded against a Measuring Point to record (Component Change) component change out. This will enable future locating of a component for replacement. Create Measurement Doc This ensures that the Work Plan will call at the correct intervals when a Counter (Counter Replacement) Replacement occurs. Why is the Maintain Plans A Work Order activity resulting in the requirement to record either qualitative or & MEasurement quantitative measurement readings. By direct entry or system enabled entry of documents Process measurement readings as Measurement Documents. The outcome is the
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Important to BHP Billiton? automatic creation of Notifications and Work Orders to support the underlying Work Strategy. Linear Objects The creation of Functional Locations (rather than standard SAP Equipment) for linear assets ensures that locations will never be moved (unless re-routed or decommissioned). The individual objects (e.g. welds) contained within each linear asset are recorded within the Characteristics of the Functional Location as Linear Objects, in a similar manner to Plant Tags. The installation or removal of a Linear Object will require the creation of a Master Data Request to update the Functional Location Characteristics. The number of Linear Objects within a Functional Location and the identification of the Functional Location in which a Linear Object is installed, is enabled by within the design. The management of Component Tracking requires that the following: Components are only tracked for a Critical Control for HSEC Material Risk or for Material Legal Risk and the Critical Controls has a recertification requirement. Components used on equipment are managed by Supply the majority of Components are to be repaired in a Planned manner. Component Tracking is enabled by the creation of Measuring Points for each of the tracked locations into which a Material is installed; the Measuring Point contains the Material Number of the installed component in the Assembly field. On the replacement of a tracked component: a Component Change-Out Measurement Document is created against the applicable Measuring Point the Measurement Document will contain the serial number of the installed component in the 'Text' field future requirements to identify the installed location of a Component being tracked are obtained by a list of Measurement Documents by Functional Location. Component tracking requires all components to be managed through the Work Management and Supply Processes; no Materials are managed in systems outside of 1SAP, including the repairs to such. Following 1SAP Processes means: the use of uncontrolled stores is not permitted. 'Blanket Work Orders (Work Orders created at a high level Technical Object to capture a wide range of activities executed beneath, over a long period of time) are not permitted for the overhaul of components Components for the repair of equipment are obtained from inventory Component repairs are not charged to the Fleet or Process area of removal, the repair costs are settled to the Material, using PM04 Work Orders or Sub-Contract Purchase Orders Work Orders are created for the repair of components, then planned and scheduled based on known quantities of components being removed from service. A single PM04 Work Order may be used for the repair of multiple Repairable Spares where the Work Order is for the same Material number. Components are returned to inventory after repair, awaiting fitment to future Fleet or equipment where a record of repair history is required to be kept, the history is recorded in a Document Information Record. Analytical data is not stored in 1SAP, but kept in a Reliability database. Determination of the level at which work will be performed on equipment will aid the structuring of Task Lists and Preventive Work Plans for the execution of work on fleet and equipment all repaired components are to be managed through the Repairable Spare/ Service Exchange process; as such all internal repairs are to utilise PM04 Work Orders and external repairs are to use Sub-Contract Purchase Orders. To effectively enable Component Tracking, the following is relevant:
Component Tracking
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Management of open-access storage areas for Catalogued Materials Management of a Damaged Storage Location for Repairable Spares. Service Exchange Items Consideration of float numbers and instigation of PM04 Work Orders from MRP Set up of Materials with regards to grouping components into single Repairable Spare Materials Creation of Task Lists for the internal refurbishment of Repairable Spares Creation of Task Lists for the replacement of Materials on Fleet and equipment Awareness of requirement to return damaged/repaired inventory promptly to ensure required Materials are available for issue Identification of opportunities to use Production Systems to automatically create Measurement Documents which drive Work Management Work Strategies. Automatically Generated For Condition-Based Work, the option for a Work Order to be generated from a Work Order or Notification Work Plan or a Notification to be generated from a Measuring Point exists. When selecting which method of automatic generation is required, the following considerations are relevant: Work Order from Work Plan - preset counter limit reached due to equipment usage - pre-determined Task List assigned to Maintenance Item/Work Plan - Work Order is created with required tasks as per Work Strategy, without. initial investigation of validity. Notification from Measuring Point - pre-set Tolerance Limits breached at an instant in time (For example cumulative deterioration, temperature, usage) - Notification Long Text contains the Measuring Point, Measuring Point Description, Measurement Document Reading, Measuring Point Upper/Lower Limit and the Measurement Document Text - no pre-determined Task List assigned to Notification, selection made from available list (This is a prerequisite for setting up a Measuring Point to trigger automatic Notification creation) - Notification can be initially scoped for validity and detail of corrective action required prior to Work Order creation. Measuring Point A Measuring Point is an SAP Master Data object that represents a location where there is a requirement to record condition (e.g. wear or pressure), usage (e.g. hours or tonnes), and component tracking data. Measurement Documents are created against Measuring Points in two ways: Manual creation against the Measuring Point which includes the creation of Measurement Documents against Event Notifications. to capture Event related data (e.g. Lost Days, Volume of Substance Released) Automatic creation against the Measuring Point through an interface from interfacing measurement systems.
Measuring Documents
1SAP allows for the creation of Measuring Points to support a Work Strategy where Measurement Documents: Trigger Work Order creation from a Counter Based Work Plan Record a Component Change Out for a Critical Control for HSEC Material Risk or for Material Legal Risk and the Critical Controls has a recertification requirement. Trigger the automatic creation of a Notification when preset tolerances are breached Recording HSEC data to support group Reporting and HSEC Metrics. Production and Reliability data, that does not drive one of the above Work Management Work Strategy relevant situations, is not recorded using the 1SAP Work Management Design; non-Work Management relevant data is recorded using non-1SAP Asset/Operation systems.
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The structuring of Work Plans to run off the upper-most Counter will simplify the Work Strategies by ensuring that the minimum number of M Type (Quantitative) Measuring Points are created. G Type (Qualitative) Measuring Points are to be created where there is a requirement to track the installation of components for a Critical Control for HSEC Material Risk or for Material Legal Risk where the Critical Controls has a recertification requirement.
Activities
Activity Create Event Measurement Document Description The objective of this activity is for the learner to create a Measurement Document against Measuring Points associated with a Notification to record instantaneous or accumulative values against the Notification.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31883?mode=EU Create Simple Measurement Document The objective of this activity is for the learner to create a Measurement Document against Measuring Points to record instantaneous, accumulative, or quality values against Technical Objects.
Link http://usdc2rsapa10.bhpb.internal/gm/folder-1.11.31887?mode=EU Create Component Change Out Measurement Document The objective of this activity is for the learner to enter a Measurement Document to record component life where there is a Measuring Point on a Functional Location.
Component : Create Measurement Readings 305.05.01.050. Create Simple Measurement Document

Step What Detail The goal of this process step is to create Measurement Documents against Measuring Points to record instantaneous, accumulative, or quality values against Technical Objects. To create a simple measurement Document, use the transaction Create Simple Measurement Document, to select the Technical Object against which the Measurement Documents are to be created perform one of the following: if creating a Measurement Documents against a Functional Location perform the following:
How
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- MeasPointObjec IFL, Click 'Enter' button, the 'FunctLocation' field is then displayed - FunctLocation Enter the Functional Location identifier and Click the 'Enter' button, the 'Collective Entry of Measurement Documents: Overview' screen is then displayed. If the functional Location is unknown perform the following: - in the 'FunctLocation' field Click the 'Possible Entries Search button, the 'Functional Location Structure: Selection' screen is then displayed. If this is not displayed when Clicking the 'Possible Entries Search' button, Click back and select 'Structural display' to bring up the selection - Navigate to the required Functional Location and double mouse Click on the Technical Object. The Functional Location is then populated into the 'FunctLocation' field - Click the 'Enter' button. The 'Collective Entry of Measurement Documents: Overview' screen is then displayed. ff creating a Measurement Documents against a Safety Critical Element perform the following: - MeasPointObjec IEQ, Click 'Enter' button, the 'Equipment' field is then displayed - Equipment Enter the Safety Critical Element and Click the 'Enter' button, the 'Collective Entry of Measurement Documents: Overview' screen is then displayed. If the Safety Critical Element is unknown perform the following: - in the 'Equipment' field Click the 'Possible Entries Search button, the 'Equipment Structure: Selection' screen is then displayed. If this is not displayed when Clicking the 'Possible Entries Search' button, Click back and select 'Structural display' to bring up the selection - Navigate to the required Safety Critical Element and double mouse Click on the Technical Object. The Safety Critical Element is then populated into the 'Equipment' field - Click the 'Enter' button. The 'Collective Entry of Measurement Documents: Overview' screen is then displayed. to create multiple Measurement Documents (Collective Entry) against the Technical Object (e.g. End of Month HSEC Reporting), select the 'All Measuring Points on Object' button at the top of the screen. All of the Measuring Points for the Technical Object will then be populated into the Measurement Documents list, ready for data entry. Proceed to create the Measurement Document as defined below: - if creating Measurement Documents via Collective Entry ensure that only the applicable Measuring Points defined within relevant business documentation is selected for Measurement Document Creation. if creating Measurement Documents for Measuring Points of Category M Counter, complete the following fields: - Meas Time In the first field enter the Date and in the second field enter the Time measurement reading is taken - Rdg/CtrRdg Enter the value of the current counter reading and then Click 'Enter' button. The value has been created if creating Measurement Documents for Measuring Points of Category C Conditioning Monitoring, note following fields: - Measurement Time - Date and Time measurement reading is taken - if creating Measurement Documents to report monthly or quarterly data (e.g. HSEC data for Group), in the first field enter the date equal to the last day of the month for the reporting period. In the second field the time equals time of Measurement Document creation. - Rdg/CtrRdg- Enter the measurement or reading recorded and then select 'Enter' button. The value has been created - if creating multiple Measurement Documents repeat the process for all Measuring Points - if performing End of Month HSEC Reporting ensure the following Measuring Points, related to Event Notifications, are not populated: - Quantity of liquid released
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- Quantity of gas emitted - Lost days (Contractors) - Last days (Employees) - Restricted work days (Contractors) - Restricted work days (Employees) if creating Measurement Documents for Measuring Points of Category G - General as part of End of Month HSEC Reporting in the 'Val' field, select the 'possible entries search button' and from the list displayed double Mouse Click on the correct qualitative value. The 'Val' field is then populated with the Value. once all Measurement Documents have been created, Click the 'Save' button (button at top of screen) - upon saving Measurement Documents should the Allowed Counter Reading Difference be breached a warning message will be displayed. This is based on the following calculation: - Allowed Counter Reading Difference = 2 x (Annual Counter Estimate/365) x Days since last reading - upon saving Measurement Documents for condition monitoring Measuring Points (Category C), if measurements or readings entered are outside the tolerance limit, a Notification is created automatically by the system. The Notification number appears in a pop up box. if multiple readings are outside the tolerance limit, multiple Notifications will be triggered automatically, however only the Notification number for the first reading tolerance limit breach will be displayed. Note: When executing this step, consideration should be given to the 'Remote Working Protocol' to determine the appropriate means of transacting.
305.05.01.060. Create Event Measurement Document

Step What Detail The goal of this process step is to create a Measurement Document against Measuring Points associated with a Notification to record instantaneous or accumulative values against the Notification. To create an Event Measurement Document continue within the current transaction, or use transaction Change Notifications' and enter the Notification number. If the Notification has been assigned a System Status of Completed (NOCO), put the Notification In Process (NOPR) by performing the following only: Click In process again button Click 'Continue when status check warning dialog box appears. Notification is then saved with the different System Status the 'Change Notifications' screen is again displayed with the Notification number already pre-populated in the Notification field, Click 'Enter'. From within the Notification perform either of the following: select Extras > Meas Documents - to create a Measurement Document on a Notification where a Measurement Document has previously been created, select the 'New Entries' button (top right), this will create a new blank field for Measurement Document creation. Proceed to locate the Measuring Point - to create a Measurement Document on a Notification where no previous Measurement Documents have been created, proceed to locate the Measuring Point. to locate a Measuring Point against which a Measurement Document is required to be created, perform the following:
How
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- in the first blank line, in the 'MeasPoint' field select the Possible Entries Search button, one of the following will occur: - The 'Display Measuring Point: Meas Point Selection' screen will then be displayed - The Functional Location screen is displayed. Select the 'New Search' button (button to the left of the red cross). From the 'Selection of Input Help' menu, select 'Measuring Point List'. - in the 'Functional Location' field, enter or select the Functional Location that represents the 'Operation, Asset, or Customer Sector Group' level of the business. These are the only Functional Locations where Event Measurement Documents are to be created - Execute the search - from the list of Measuring Points, select the required Measuring Point by highlighting the line on one of the following: - Quantity of liquid released - Quantity of gas emitted - Lost days (Contractors) - selected only when performing Work Plan generated HSEC reporting activities - Lost days (Employees) - selected only when performing Work Plan generated HSEC reporting activities - Restricted work days (Contractors) - selected only when performing Work Plan generated HSEC reporting activities - Restricted work days (Employees) - selected only when performing Work Plan generated HSEC reporting activities. - Select 'Choose' button (Green Tick). The Measurement Document is then created for the Measuring Point. in the 'Rdg/CtrRdg' field enter the quantitative value for the Measurement Document. Then Click 'Enter' button. The Measurement Document has been created. Measurement Time - To enter Measurement Time and date perform the following: - if creating Measurement Documents to record Lost Days or Restricted Work Days enter the date equal to the last day of the month for the reporting period. The time equals time of Measurement Document creation - for all other Event Measurement Documents, leave unchanged from default current date and time. additional Free Text Description - If an additional free text description is required to enable unique cross-reference identification between the Measurement Document and Notification or provide further information on the Measurement Document (e.g. there may be more than one injury with lost / restricted days associated with a single Event or there may be a specific type of substance that has been released into the receiving environment), this is to be recorded in the Notification Long Text by performing the following: - obtain the Measurement Document Number by performing the following: - Highlight any field within the Measurement Document field (e.g. 'Rdg/CtrRdg' field') - Select 'Measurement Document' button (top left corner - located to the left of the 'trash bin' button). The 'General Data' screen will then be displayed' - Click the Execute Transaction Button located top left of screen - Copy or note the Measurement Document number listed in the 'MeasDocument' field. - Return to the Notification Header Long Text by selecting the 'back' button (green button with white left arrow at top) four times. The Notification header screen will then be displayed - in the Notification Long Text enter the Measurement Document number (identified previously) and any additional free text information (e.g. Notification Item number if there is more than one injury involved lost or restricted days; specific substance released). If a Measurement Document is being created to record lost days or restricted days
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ensure the 180 calendar day limit of lost days or restricted days per injury per injury has not been exceeded by performing the following: to calculate the total restricted or lost calendar days review the previously entered Measurement Documents and sum the previously entered Measurement Document readings. - if there is more than one Item of Impact Type = Safety and Actual Severity = 3, review the Notification Long Text to identify which Injury (Notification Item) the Measurement Document is associated with. if the Measurement Document was to be created for an injury that already has 180 days assigned, then Measurement Document Creation is not required if the Measurement Document was to be created for an injury that is approaching the 180 day limit, and the intended Measurement Document figure will breach the 180 day limit, then only enter a value for the Measurement Document that will ensure the total lost or restricted days will equal 180 days. If an additional Event Measurement Document is required, repeat the process above. Where all Measurement Documents have been created, return to the Notification screen by selecting the 'back' button (green button with white left arrow at top). To finalise the Notification perform one of the following: if the Notification was opened for Measurement Document creation and the status was changed from Notification Complete (NOCO) in order to create the Measurement Document, then complete the Notification by selecting the 'Complete' button if the Notification was opened for Measurement Document creation and status has unchanged to create the Measurement Document, save and Exit the Notification if the Measurement Document was created as part of Notification Evaluation activities then continue in the current transaction.
305.05.01.070. Create Component Change Out Measurement Document

Step What Detail The goal of this process step is to enter a Measurement Document to record component life where there is a Measuring Point on a Functional Location. A Measurement Document must be created to record the component life (e.g. The life of the component needs to be recorded). To create a Measurement Document, use the transaction Create Measurement Document, ensure the following fields are completed: Measuring Point - Enter the Measuring Point or search by Functional Location. Component Change Out Measuring Points are of Category G, complete the following fields: MeasurementTime - Enter the date and time the reading was taken Text - Enter the Serial Number of the installed Material (Where no serial number exists a local plant identifier may be entered in lieu) Valuation Code - Component Changeout.
How
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Name Compliance to Work Plan Description Compares the number of finished system generated Work Orders in the period within tolerance, to the number of finished system generated Work Orders in the same period. Defines the number of Occupational Illnesses that have occurred within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Type 1 Water Input The total volume of Type 1 water which is received by the operational facility, or which has become available from within the operational facility, from surface water, groundwater and third party water sources within the period. Type 1 water is close to drinking water standards. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application. Greenhouse Gas Emissions Defines the total amount of Greenhouse Gas Emissions produced within the period. The measure is for 'controlled activities', which are activities where BHP Billiton sets workplace HSEC standards and enforces their application.
Occupational Illnesses
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Level 3: 305.05.03. Maintain Data Quality

The Maintain Data Quality process includes the review and rectification of errors in the Error Logs and Time Confirmations. A review is conducted for Annual Measuring Point Estimates, Work Center Activity Rates. Damaged Repairable Spares/Service Exchange Items are managed and repaired spares are inspected.
Process Components
Figure 1: Process Components Component Manage Work Plans and Deadline Monitoring Rectify Measurement Document Errors Review Work Center Plan / Actual Rates Locate Object Information Description The purpose of this component is to review Deadline Monitoring errors when managing Work Plans. The purpose of this component is to explain how to rectify Measurement Document errors. The purpose of this component is to explain how to review Work Center plan / actual rates. The purpose of this component is to explain the process of identifying the location of Technical Objects and Material history. The purpose of this component is to explain how to rectify Time Confirmation errors. The purpose of this component is to explain how to manage the return of overdue damaged Repairable Spares back to Store for refurbishment. The purpose of this component is to explain the process of re-printing Shop
Rectify Time Confirmations
Manage Repairable Spares
Reprint Shop Papers
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Papers when executing work. Manage Certified Material The purpose of this component is to explain the management of technical and quality inspections relevant to certified material.
Upload Activity Spreadsheet for The purpose of this component is to explain how to populate the monthly Finance Activity Upload Spreadsheet with residual hours from Work Order Operations.

Key Concepts related to Maintain Data Quality process are outlined in this section. Concept Description
Why is the Maintain Data Maintaining data quality is managed on daily, weekly, monthly and yearly basis. Quality Process Important The Maintain Data Quality process includes the following activities: to BHP Billiton? - Reviewing Work Plan Deadline Monitoring errors - Reviewing annual counter estimates - Reviewing planned Activity Rates on Work Centers - Rectifying Work Order closure issues - Inspecting Material repairs - Locating defective materials - Reprocessing and cancelling Time Confirmations - Rectifying Measurement Documents - Uploading Activity spreadsheets for Finance. Master Data and Transactional Data is reviewed in 1SAP and acted on accordingly. Data errors are corrected and where applicable, Master Data Management requests are submitted to the Master Data Organisation for data creation and change consideration. Certification and Quality Inspection All Repairable Spares are required to be inspected prior to being made available in Inventory. The Material Masters for these items are set to Quality Inspection (QI) such that they are held in Quality Store until they have passed inspection. Each Operation is to have an appointed person to perform the role of Spare Part Inspector (Work Strategy Global Job Group). The Spare Part Inspector is to inspect the quality of the repair on both internally and externally repaired spares to ensure they are fit for service. Additionally, the Spare Part Inspector will assess the Inspection Certificates for Certified Material to ensure that they have been correctly certified. The report of the Material Repair or Certification Documentation is linked to an SAP Document Information Record. For ease of retrieval, the Document Information Record will contain the Material Number and Manufacturers Serial Number of the repaired or certified Material in the Characteristic Values. User Defaults To enable the ease of downstream transactional processing, the following parameter defaults are to be set up for all Work Management Global Job Groups. Parameter IDs Listed below are the minimum Parameter IDs (PIDs) that are required to be set up for Work Management Global Job Group Holders: BUK (Company Code) - User Specific CAC (Controlling Area) - User Specific SWK (Maintenance Plant) - User Specific WRK (Work Center Plant) - User Specific
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PIN (Task List Profile) - 1SAP_01. User Default Values Listed below are the minimum Work Order User Default Values that are required to be set up for Work Management Global Job Group Holders. External Processing tab: Goods Recipient - User Specific User ID Unloading Point - User Specific Location Purchasing Group - User Specific. External Procurement tab: Recipient - User Specific User ID Unloading Point - User Specific Location Purchasing Group - User Specific. Review Annual Counter Estimates Key reasons to Review the Annual Counter Estimate: - increased or reduced usage of equipment - changed operating conditions e.g. Dump Truck move from Mining Department to Pre-striping Department - altered Production plan e.g. ramped up Production - age of equipment or plant e.g. changed usage to control equipment lifespan. Unreturned Repairable Materials affect future work execution and part availability by limiting the turn around time of repaired spares and sourcing of new materials. In addition, this may impact Schedule Adherence Metrics. The result of performing quality and technical inspections of internally and externally repaired Repairable Spares are: - commonality of repair standard - validation of Spare certification - history entered for Material.
Managing Unreturned Damaged Repairable Spares Perform Technical Inspection
Activities
Activity Cancel Time Confirmation Description The objective of this activity is for the learner to cancel an incorrectly entered Time Confirmation, due to a Time Confirmation being entered with incorrect data.
Component : Rectify Time Confirmations 305.05.03.070. Cancel Time Confirmation

Step What Detail The goal of this process step is to cancel an incorrectly entered Time Confirmation, due to a Time Confirmation being entered with incorrect data, including: confirmation against wrong Personnel confirmation against wrong Work Order Operation confirmation entered with incorrect Final Confirmation indication set
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confirmation with incorrect hours. How To Cancel an incorrectly entered Time Confirmation, use transaction 'Display Confirmations (Selection List)' and perform the following only: Plant (Planned) - Enter the Planned Plant Personnel number - Enter number if known Work Center (Plan) - Enter the Planned Resource Work Center Entered on - Enter date range to narrow the search Execute Transaction. Select the Time Confirmation to be cancelled and from the menu path select Completion confirmation>Cancel Click the 'Save' button Click back.
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Name Compliance to Work Plan Description Compares the number of finished system generated Work Orders in the period within tolerance, to the number of finished system generated Work Orders in the same period.
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Level 1: 303. Inventory Management

Manages planning, execution and optimization of inventory related to finished products, raw materials, packaging, spares and consumable materials. This is to ensure customers, maintenance and production have exactly what they need when they need it. In addition, provides the review and analysis of key performance indicators and compliance reports for management at various levels to monitor and take action in achieving performance targets and audit compliance to support strategic goals. Successful inventory outcome is properly managed by minimising stock outs and maximising return on capital.
BHP Billiton
303. Inventory Management
Owner: Steve Clifford Engineer: Alok Sharma
Type: Value-added chain diagram
303. Inventory Management
303.01. Warehouse and Stock Management
303.02. Inventory Planning
303.03. Inventory Monitoring and Controlling

Key Concepts related to Inventory Management process are outlined in this section. Concept Description
Why is Inventory The importance of Inventory Management Process to BHP Billiton is to optimize Management important to working capital while ensuring materials are planned, stored, maintained and BHP Billiton? transported to support the operations and meet customer requirements. Stocking strategies are assessed for all materials, stocks are regularly reconciled and slowing moving/obsolete stock is reviewed for further action. Inventory Management: Did you Know? What are the key measures of success for Inventory Management? The 1SAP Inventory Management processes use the Oniqua Analytics Suite (OAS) software as well as the 1SAP system to assist us in managing our inventory. The key measures for the success of Inventory Management are: - service levels maintained - stock levels optimised
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- stock balances accurate - stock available to meet requirements dates - stock maintained in usable condition - surplus and obsolete stock managed
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Level 2: 303.01. Warehouse and Stock Management

Verifies and records receipt of goods/products from suppliers, for stock transport orders, returns or products from production. Inspects and approves inbound procured or repaired goods for compliance with safety and technical specification requirements. Stores goods safely in various storage locations. Records outwards goods or product movements due to consumption, repair, assembly, sales or transfer between locations. Records returns of no longer required items, rental equipment or damaged spares. Facilitates the physical delivery of goods/products from the warehouse or stock point to either an internal or external delivery point. Facilitates the physical stock count, adjustment, scrapping and material to material transfer for product reclassification.
Level 3 Processes

Key Concepts related to Warehouse and Stock Management process are outlined in this section. Concept Why is Warehouse and Stock Management Description The importance of the Warehouse and Stock Management Process is to maintain stock accurately and in good working condition so that it is available to support the
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important to BHP Billiton? operations and meet customer requirements. Warehouse and Stock Management: Did You Know? The processes of Warehouse and Stock Management are governed by GLD.027 Supply 'Plan to Pay'.
What is Remote Logistics Remote Logistics Management (RLM) is a module in 1SAP used to manage the Management (RLM)? logistics-related activities of remote sites. RLM manages material movements and tracking of material movements for both stocked and non-stocked materials, including both inbound and outbound shipping, and the rentals and returns cycle. RLM works on the basis of a 'Supply Process'. What is a 'Supply Process'? The Supply Process in RLM defines what actions need to be taken to meet a particular material request. This is done using a combination of 1SAP configuration and master data settings. These settings determine the particular scenario at certain key points in the process and the appropriate next action in that scenario based on the supply process defined. For instance RLM will determine if a material specified in a Work Order should generate a reservation, a stock transport requisition, or a purchase requisition. What are the Advantages RLM has the following advantages: of RLM? - Integrates logistics and transportation functionality and reporting: - material demand document (STO or PO) is automatically generated when required - supply chain documents are linked, providing improved material tracking - Improves supply of materials from base location: - materials delivered 'right-on-time' - material demand documents are generated automatically based on the stocking strategy - Reduces administration: - subsequent actions from Goods Receipt at base location are automated using an onward shipping function - Improves returns process from remote location: - the Goods Return automatically creates subsequent documents helping remote location staff determine follow on actions - Enhances supply and return of rental equipment: - controls dispatch of rental equipment via a rental PR type - supports return of rental equipment to base - Simplifies the process for the Work Management audience: - the Work Order processor need only specify the materials they need, how much, and when. Advantages of Goods Receipt Cross Docking When a material is delivered from a supplier to the base location, instead of processing the material into stock at the base location, it is immediately shipped onward to the remote location requiring the material. Cross-docking is in effect an interface between the goods receipt and RLM shipping. It allows use of the Goods Receipt Packing functions from within a goods receipt. This adjusts the default packing treatment of goods receipt items, so that they can be shipped according to the required packing requirement. The goods receipt cross-docking function enables more efficient handling of materials and minimises unnecessary material double-handling, thus reducing cycle times, and inventory and handling costs.
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In addition, all subsequently created documents are linked back to the document that initiated the demand, e.g. a Work Order. When the goods are delivered at the remote site, shipment receipt is performed using the standard shipment receipt transaction. Advantages of RLM Material Tracking RLM provides better integration between demand planning and supply provision via improved status tracking as documents are linked to show progress through the various stages of the supply chain. RLM provides reports that consolidate all supply chain documents together. These reports answer common questions such as: - has the purchasing department ordered the material? - has the supplier delivered it? - has it been loaded onto delivery transport? - when will it be shipped? - when did it arrive at the worksite? This kind of information can be requested via the common request documents: - Work Orders - Network Orders (for Shutdowns) - Purchase Requisitions - Stock Transport Requisitions - Goods Receipts - Returns documents. Using RLM for Rental Equipment Rental of equipment is usually handled using standard services functionality. This allows payment of hire charges and other fees. However, where it is necessary to control the dispatch of rented equipment to remote locations, this control is possible by activating rental functionality available in RLM. Rental functionality is activated by assigning a specific service category. In the work order or requisition, a service line item which belongs to the assigned rental category has an additional tab called Mobilisation. In the Mobilisation tab additional information is entered, such as rented material number, quantity, and number of packages expected to be received. A free text field for capturing the supplier reference is also available. Initially the mobilisation status should be set to Waiting. From this point onward, the 1SAP system automatically sets the mobilisation status based on the progress of the rental activity. Rental Purchase Orders When the requisition is turned into a purchase order, 1SAP automatically adds non-valued material items according to the number of packages specified in the mobilisation tab. With this material item, it is possible to use other RLM functionality such as automatic delivery creation via cross-docking and packing, to receive and dispatch rented materials and equipment to a remote location. In 1SAP, there will be seven Supply Processes to cover for all possible RLM scenarios. Your CSG may use some or all of these. The scenarios are as follows: Supply Process 01 Stocked at both remote and base location Supply Process 02 Stocked at base location only Supply Process 03 Stocked at remote location only; delivery from vendor via the base Supply Process 04 Non-stocked; delivery from vendor via the base Supply Process 05 Non-catalogued; used for free-text items; delivery from
How to Activate RLM for Rentals
What Scenarios are Catered for in RLM?
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vendor via the base Supply Process 06 Non-stocked; used for catalogued or free-text items; delivery is direct from vendor Supply Process 07 Stocked at remote location only; delivery is direct from vendor. How are Repairables Managed? The management of repairable spare items such as mechanical, electrical, electronic, hydraulic components is critical to the support of our operations. This process is essential to ensure sufficient spares are stocked on-site to minimise downtime of critical infrastructure, or of fixed and mobile plant equipment, and it also assists to reduce costs. The repairables process is triggered from a work order. The following steps occur: 1. To get the NEW / REPAIRED item, a positive reservation is created from the Work Order (WO). 2. To return the DAMAGED item, a negative reservation is created from the WO. 3. MRP settings will determine if either a Subcontract Purchase Requisition (PR) is created or an Planning Order is created. For the Subcontract PR case: 4. If it is determined, based on MRP settings, that the item be repaired by a vendor, a subcontract Purchase Order (PO) is created. The item (and any related materials) are issued to the supplier, and the Goods Receipt (GR) posted when the material is returned in its repaired state. For the Planning Order case: 5. The Inventory Planner needs to make the decision if the item can be repaired internally or should be repaired by a vendor. 6. If the decision is to repair the item internally a "PM04" work order is created. 7. If the decision is to repair the item externally, a subcontract PR must be manually created and, then follow scenario 4. How are Service Exchange Materials Managed? The Service Exchange process, which is based on the 1SAP standard external procurement process, is used to effectively handle the externally serviced major components for mobile and fixed plant equipment, e.g. diesel engines, transmissions, tanks, motors, etc. MRP Controller "Service Exchange" (016) is used to identify Service Exchange materials. In the Service Exchange process the working spare will be requested via a reservation and a negative reservation will be used to return the DAMAGED component to the store; The Purchase Order will include a return item to track the return of the DAMAGED component to the vendor, after evaluation the vendor will issue a credit note to recognize the value of the core. Note that in cases where there is a legal / tax constraint for the credit note the 1SAP Sundry Sales process is used instead of the credit note. What is a Repairable? A repairable spare is defined as an object that has the potential to be re-built or repaired to near original equipment manufacture (OEM) specifications and put back into operational service to meet operational design performance standards, at a cost less than replacement value. Typically the cost would be 75% or less than replacement cost. The re-built item must be capable of meeting the operational design functionality requirements of performance and life. All repairable spares shall be catalogued, each repairable spare shall be classified as New, Damaged, Repaired or Scrapped.
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Level 3: 303.01.04. Process Goods Issue

Records outwards goods or products movements due to consumption, repair, assembly, sales or transfer between locations. Goods/products are issued referencing reservations, subcontract orders or stock transport orders. A pick list is used to facilitate the picking of goods and is generated based on the delivery requirement dates. If immediate goods issue is required, the goods are picked without waiting for the pick list to be run only if a valid reservation is provided.
Process Components
Figure 1: Process Components Component Process Goods Issue Description Records outwards goods or product movements due to consumption, repair, assembly, sales or transfer between locations. Goods/products are issued referencing reservations, subcontract orders or stock transport orders. A pick list is used to facilitate the picking of goods and is generated based on the delivery requirement dates.

Key Concepts related to Process Goods Issue process are outlined in this section. Concept The Goods Issue POWL Posting a Goods Issue Using MIGO Types of Goods Issue Description The Goods Issue POWL allows you to quickly view all Outbound Deliveries relevant to you. Restrict the selection criteria to your Plant. The MIGO Transaction 'Goods Issue action', is used to process all Goods Issues (except subcontract purchase orders). Choose the Goods Issue action and then choose the reference document, e.g reservation. The following kinds of Goods Issue may be required: - reservation - negative reservation - refurbishment - return damaged spare to base - transfer slow moving stock - scrapping.
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Component : Process Goods Issue 303.01.04.060. Sign as Required and Collect Goods
Step What How Detail The goods issue slip is used to identify the unloading point and goods recipient. To collect the goods and acknowledge receipt of goods. Self collection of goods is carried out by end-users or Suppliers once the goods have been issued from stock. The goods issue slip is used to identify the unloading point and goods recipient.
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Level 2: 303.02. Inventory Planning

Facilitates forecasting and optimization of inventory reorder points to minimise excess stock and maximise stock availability, and includes the management of new, surplus, or obsolete materials. Replenishes stock to fulfil requirements from work management in a timely manner, and plans the movement of traded commodity materials along the value chain. Records demand for stocked materials to be made available for work management according to the requirements date. Initiates a work order for internally repaired spares or site manufactured goods that are stocked materials.
Level 3 Processes

Key Concepts related to Inventory Planning process are outlined in this section. Concept Description
Why is Inventory Planning The importance of the Inventory Planning Process is to optimize working capital important to BHP Billiton? while ensuring materials are planned to support the operations and meet customer requirements. Inventory Planning: Did You Know? What is the Oniqua Analytics Suite? BHP Billiton manages a significant inventory in support of our operations and issued approximately 1.7 million materials against reservations in 2010. The Inventory Planning process uses OAS, a decision support system, for calculating optimal inventory holding levels. OAS maintains five years of inventory transactional data to support detailed analysis and data quality. It works along with the Materials Management system to provide sophisticated inventory optimisation. OAS facilitates better inventory planning as it helps to balance: - investments made on inventory - operational costs of the supply department - expense of running out of stock.
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Level 3: 303.02.03. Process Reservation

Records demand for stocked materials to be made available for maintenance or production according to the requirements date. This demand is captured via reservations released from work orders or direct creation and are taken into account during materials requirement planning. If materials are not available to satisfy the demand, the purchasing or stock transfer request will be triggered. This excludes non-stocked direct charge materials which are ordered via a requisition.
Process Components
Figure 1: Process Components Component Search, Create, Change and Review Reservations Run Pick List Description This component describes the steps involved in the search, creation, change and review of reservations. This component describes the steps associated with a pick list run.
Component : Search, Create, Change and Review Reservations 303.02.03.015. Search to Find Existing Material Master
Step What Detail Searching for materials catalogued in the system is carried out to check if the item exists and also to check if the material is stocked or non stocked. Stocked materials are requested via a reservation and non stocked materials are ordered using a direct charge purchase requisition. To search for Catalogued Material: - select the link "Stock Overview" (transaction MMBE) - enter a Material, Plant, Storage Location as required and execute the transaction.
How
303.02.03.030. Search and Review Existing Reservation

Step What Detail Reviewing the reservation status is carried out to check if the items have been issued prior to deciding if the reservation can be changed or if a new reservation is to be
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created. How To Review the reservation status: - select the link "Reservation List" (transaction MB25). It will enable the search of Reservations depending on the parameters specified in the search query. As a minimum, enter Plant and Reservation due date to restrict the search results.
303.02.03.040. Determine if New Reservation is Required

Step What Detail Decides if a new reservation is required when the initial reservation has been issued and a change to increase the quantity of materials is required. To determine if a new reservation is required, review if the initial reservation has been issued, if the reservation has not been issued, or change it to increase the quantity of the materials required.
How
303.02.03.050. Create Reservation

Step What Detail Reserving catalogued materials places a demand on the stock system and is carried out so the material will be available for use based on the requirements date. If not enough stock is available the system will trigger the Materials Requirements Planning and Purchasing processes to satisfy the requirement. Once the stock is available and due, the materials are picked and delivered or collected. Special attention should be taken when creating reservations for Service Exchange Materials (e.g. in Chile). WBS, vendor name and vendor number need to be clearly specified in the reservation to facilitate the creation of a sundry invoice at a later stage. How To Create Reservation: - select the link "Create Reservation" (transaction MB21). Create Reservations for reserving catalogued materials places a demand on the stock system and is carried out so the material will be available for use based on the requirements date - if not enough stock is available the system will trigger the Materials Requirements Planning and Purchasing processes to satisfy the requirement - once the stock is available and due, the materials are picked and delivered or collected.
303.02.03.060. Change Reservation

Step What Detail Changing item details is carried out as required and may include changes to quantity, costing and unloading point. This can be due to mistakes in the original reservation or a change in the requirements. If the original reservation was created from a work order, then the change needs to be done via the work order and not via the direct change reservation transaction.
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How
To Change Reservation: - select the link "Change Reservation" (transaction MB22) - select the Reservation to be changed - change relevant information, e.g. material number, quantity, due date, cost object.
303.02.03.070. Review Reservation

Step What Detail Reviewing reservation item details is carried out to confirm reserved item codes, description, quantities, cost code and requirement dates are correct so there is no delay for the follow on processes. To Review reservation item details: - select the link "Display Reservation" (transaction MB23) to confirm reserved item codes, description, quantities, cost code and requirements dates are correct so there is no delay for the follow on processes.
How
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Name % of Planned Reservations Satisfied On-Time And In Full Description % of Planned Reservations Satisfied On-Time And In Full metric provides the total number of stock reservations satisfied on time and in full. This is a count of the number of stock reservations issued prior to the calculated requirement date
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Level 1: 405. Master Data Management

Master Data Management describes the Master Data request driven main process for the following process areas: - Manage Work Management Master Data - Manage Supply Master Data - Manage Finance Master Data - Manage Marketing Master Data (includes Production Integration) - Manage Human Resources Master Data - Master Data Management Monitoring and Controlling - Master Data Process and Quality Management - Escalate Master Data Request The first five are stream specific and governed by a specific Master Data Organisation ensuring compliance with the Master Data Designs. All these process areas are based on the common template that prescribes 4 steps: Data Request; Business Approval; Governance Approval; Data Processing.
BHP Billiton
405. Master Data Management
Owner: Steve Clifford Engineer: Miguel Barbosa
Type: Value-added chain diagram
405. Master Data Management
405.01. Manage Work Management Master Data
405.02. Manage Supply Master Data
405.03. Manage Finance Master Data
405.04. Manage Marketing Master Data
405.05. Manage Human Resource Master Data
405.06. Master Data Management Monitoring and Controlling
405.07. Master Data Process and Quality Management
405.08. Escalate Master Data Request

Key Concepts related to Master Data Management process are outlined in this section. Concept Description
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Why is the Master Data 1SAP is based on two pillars, common data and common processes. The design Management Process intent of the Master Data Management main process is to: important to BHP Billiton? - archive common data - ensure compliance with the Master Data Designs - provide business ready Master Data that supports common processes. Master Data Management As part of the Master Data Management process, Assets and Customer Service (MDM) Process Groups play a key part in adhering to the 1SAP Master Data Design. When a change to centrally governed Master Data is required, the business will initiate, submit, and complete the business approval on a 1SAP Master Data Request before it routes to the 1SAP Master Data Organisation (MDO) for processing. All submitted requests must be in compliance with the 1SAP Master Data Design documents. Data Originator The Data Originator initiates the 1SAP Master Data Request Form, providing all the details and supporting documentation. The request is then emailed to a Data Requestor within their business unit. This role is assigned to all Global Job Groups. The Data Requestor submits the 1SAP Master Data Request Form via the BHP Portal, providing all required detail and necessary supporting documentation in compliance with the Master Data Design documents. The necessary system checks are performed in 1SAP such as duplication, integration, and transactional data checks prior to submitting the request to a Business Approver within their business unit for approval. The Business Approver ensures the request is correct from a business requirement perspective by reviewing the request and supporting documents. The requests are approved or rejected via their Universal Work List (UWL) on the portal. The Data Steward provides governance review and approves or rejects Master Data requests submitted by the business. This comprises data duplication, Master Data Design compliance, and data integration checks for all Master Data requests. They are also the escalation point for any data processing issues. The Data Steward can add information, accept or reject a request but they cannot change the request. The Data Processor processes approved requests in compliance with the Master Data Design documents. Any process issues are escalated to the Data Steward.
Data Requestor
Business Approver
Data Steward
Data Processor
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Level 2: 405.01. Manage Work Management Master Data

Manage Work Management Master Data process describes the day-to-day operations for the centrally maintained master data. Business Process Objectives and Purpose - Submit, approve and execute requests for centrally-maintained Master Data - Maintain CSG/Asset specific Master Data Involved Central Work Management Business Objects Functional Location Safety Critical Element (Equipment) Assembly Bill Of Material Measuring Point Task List Work Plan (Maintenance Plan) Maintenance Item Work Center Shutdown Revision Marketing/Production Integration Work Center Marketing/Production Integration/Supply BOM
Level 3 Processes

Key Concepts related to Manage Work Management Master Data process are outlined in this section. Concept Why is the Manage Work Management Master Data Process Important to BHP Billiton? Description The Manage Work Management Master Data Process is important to BHP Billiton because it provides guidance on how to submit, approve, and execute requests for centrally-maintained Master Data and maintain Customer Sector Group/Asset specific Master Data.
Overview: Request and The business performs this procedure whenever new Work Management Master Approve Work Data is required (i.e. create) or whenever existing Work Management Master Management Master Data Data needs to be updated (i.e. change or delete). Business approved Work
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Management Master Data Requests are monitored by Work Management Data Stewards in the central Master Data Organisation (MDO) for governance approval. Overview: Govern Work This is the process for the governance, monitoring and approval of Work Management Master Data Management Master Data Requests. It provides a process for checking: Request - duplicate data - cross stream data integration - object dependencies - Master Data Standards compliance checks. Overview: Process Master Data Work Management Objects Overview: Process Master Data Marketing/Production Integration Work Center Overview: Process Master Data Marketing/Production Integration/Supply Bill of Materials (BOM) This process details how to execute centrally maintained Work Management Master Data Requests that have achieved governance approval. This process details the data execution of centrally maintained Work Management Master Data requests that have achieved governance approval. The Work Management Data Processor in the central Master Data Organisation (MDO) completes the data execution for the governance approved Work Management Master Data request. This process details how to conduct data execution of centrally maintained Work Management Master Data Requests. The requests will have previously been approved by governance. The Work Management Data Processor in the central Master Data Organisation (MDO) completes the data execution for the governance approved Work Management Master Data request.
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Level 3: 405.01.01. Request and Approve Work Management Master Data

The business performs this procedure whenever new Work Management Master Data is required (i.e. create) or whenever existing Work Management Master Data needs to be updated (i.e. change or delete). Business approved Work Management Master Data Requests will be monitored by Work Management Data Stewards in the central Master Data Organization (MDO) for governance approval. Work Management Master Data Request Forms: * Work Management Objects * Marketing / Production Integration Work Center * Marketing / Production Integration / Supply BOM.
Process Components
Figure 1: Process Components Component Description
Originate Master Data Request The purpose of this component is to outline originating a Master Data request. The business performs this process whenever new centralized master data is required or existing centralized master data needs to be updated. Based on the business object update required, the business selects the applicable Work Management master data request form/template for completion. To complete the form the business completes the mandatory and non-mandatory fields for the master data request scenario selected on the Work Management Objects Form. The Data Requestor will upload the form online and validate the business scenario. Duplicate Check The purpose of this component is to show how the Work Management Data
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Requestor performs data duplicate checks on the Work Management Objects Form using data verification tools, such as standard SAP transactions. Compliance Check The purpose of this component is to outline when the Data Requestor validates the request against the Master Data Design documents to ensure that the request can be executed such that the standards are adhered to. If it is found that the request would result in non-compliant 1SAP data, the request will be either amended or shall not progress to the Business Approver. The purpose of this component is for the Data Requestor to verify the integration of the requested data on the Master data Request Form with the 1SAP data set. The Data Requestor identifies any additional objects that are impacted by the Master Data request. The purpose of this component is to outline how the authorized requestor validates the information on the Master Data Request form via on-line (system) validation. The authorized requestor gathers the pre-approvals and supporting documentation required for the business object request and attaches them to the Master Data Request. The authorized requestor submits the online Form via the 1SAP Portal after validation. Notification and workflow are triggered upon the form submission. The purpose of this component is to outline how the workflow automates delivery of the approval request to the authorized business approver assigned for the form type. The business approver reviews the master data request and the attached documentation via the 1SAP workflow. The business approver will not add or change anything in the request form. The business approver will approve or reject the master data request based on the business validity of the request.
Integration Check
Validate and Submit Master Data Request
Approve Master Data Request

Key Concepts related to Request and Approve Work Management Master Data process are outlined in this section. Concept Functional Location Description A Functional Location is a multi-level, hierarchical structure organised according to functional, process-related, or spatial criteria. Functional Locations may represent a position within a business where: - a piece of plant (e.g. Mobile or Fixed) is located or a major production fleet unit operates - Measuring Points are located to support recording data for Management Reporting - Event Investigations are performed. A Functional Location is created for the purpose of: - structuring of Plant maintainable assets - identifying the location of Events - execution of tasks - recording of tasks - data collection over long periods of time - cost monitoring including budgeting by area.
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Within an existing Plant, new Functional Locations may be created for: - new maintainable assets purchased - replacement of an existing maintainable asset - new Projects identified where personnel are physically located. Safety Critical Element A Safety Critical Element (SCE) is a Critical Control that is mitigating or eliminating Material risk for Health, Safety, Environment, Social/Cultural, Reputation and Legal Statutory (where the Critical Control has a recertification requirement). Safety Critical Elements have maintenance plans and Tasks Lists assigned that address the Critical Control performance standard for mitigating or eliminating the Material Risk represented by the Critical Control. As a result of a Risk Assessment performed by the business that identifies the Material Risks and the Critical Controls required to mitigate or eliminate the risks. Maintenance Assemblies are Materials of SAP Material Type IBAU (Maintenance Assembly), utilising Basic Data 1 and Basic Data 2 and Classification Material Master Screens. SAP definitions include: - a Maintenance Assembly is not an object. It is a material type of SAP object Material Master - Maintenance Assemblies are used in Work Management Technical Object Construction Types, Bills of Material, and Task Lists. Within the 1SAP design, Maintenance Assemblies include: - a Construction Assembly is a non-plant specific Material Master object which is created using material type IBAU (Maintenance Assembly), that represents similar pieces of Plant or SCE (Safety Critical Element) with the same construction and Maintenance Strategy - a Sub-Assembly is a non-plant specific Material Master object which is created using material type IBAU (Maintenance Assembly), that represents a logical grouping of Bill of Material Components. Sub-Assemblies may also form a Bill of Material structure. Notifications and work orders are never created with reference to a Sub-Assembly within the plant structure; they are only used for Bill of Material structuring. Sub-Assemblies are non-plant specific and shall always contain a generic and non-plant or object-specific description. Integration with Assembly A maintenance object is described by the construction type assembly, which can only contain sub-assemblies and no direct inclusion of Bill of Materials is allowed for construction type assembly. The sub-assemblies can contain additional sub-assemblies or Bill of Materials. Work Strategy The Work Plan is a routine of tasks allowing the creation of Work Orders. It also provides a start date for the Cycle(s) contained within the Maintenance Item assigned in addition to other default settings. Several Maintenance Items may be assigned to the same Work Plan within the same Planning Plant. How and Why Planned dates are determined from the following elements: - Maintenance Strategy, which sets the rule for the sequence of planned work e.g. by month, kilometres or operating hours - Performance-Based Strategy plan calls are influenced by the last Measurement Document and the Annual Estimate on the Measuring Point referenced in the Work Plan - the start date of the schedule - the last Completion Confirmation - scheduling parameters, such as Shift Factor, Scheduling Indicator, and Cycle Modification Factor
Two Categories of Maintenance Assembly Maintenance in 1SAP Design
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Call dates are determined from the following elements: - planned dates - Call Horizon - Sort Field Work Plans combine information from Task Lists and Maintenance Items, and trigger regular creation of Work Orders based on assigned Strategies via a Deadline Monitoring batch job. A Work Plan may be used to schedule work for one or more Maintenance Items. A Work Order is created for each Maintenance Item assigned to the Work Plan. Deadline Monitoring variants have been created as part of the 1SAP design. The variants call Work Orders based on the Work Plan Sort Field value. The Sort Field value should allow enough lead time to fully plan and schedule the called Work Order prior to the planned date of execution. Types of Work Plan The Work Plan is a routine of tasks allowing the creation of Work Orders. It also provides a start date for the Cycle(s) contained within the Maintenance Item assigned in addition to other default settings. Several Maintenance Items may be assigned to the same Work Plan within the same Planning Plant. How and Why Planned dates are determined from the following elements: - Maintenance Strategy, which sets the rule for the sequence of planned work e.g. by month, kilometres or operating hours - Performance-Based Strategy plan calls are influenced by the last Measurement Document and the Annual Estimate on the Measuring Point referenced in the Work Plan - the start date of the schedule - the last Completion Confirmation - scheduling parameters, such as Shift Factor, Scheduling Indicator, and Cycle Modification Factor Call dates are determined from the following elements: - planned dates - Call Horizon - Sort Field Work Plans combine information from Task Lists and Maintenance Items, and trigger regular creation of Work Orders based on assigned Strategies via a Deadline Monitoring batch job. A Work Plan may be used to schedule work for one or more Maintenance Items. A Work Order is created for each Maintenance Item assigned to the Work Plan. Deadline Monitoring variants have been created as part of the 1SAP design. The variants call Work Orders based on the Work Plan Sort Field value. The Sort Field value should allow enough lead time to fully plan and schedule the called Work Order prior to the planned date of execution. The Work Plan is a routine of tasks allowing the creation of Work Orders. It also provides a start date for the Cycle(s) contained within the Maintenance Item assigned in addition to other default settings. Several Maintenance Items may be assigned to the same Work Plan within the same Planning Plant. How and Why Planned dates are determined from the following elements: - Maintenance Strategy, which sets the rule for the sequence of planned work e.g. by month, kilometres or operating hours - Performance-Based Strategy plan calls are influenced by the last Measurement Document and the Annual Estimate on the Measuring Point referenced in the Work Plan - the start date of the schedule - the last Completion Confirmation - scheduling parameters, such as Shift Factor, Scheduling Indicator, and Cycle
Work Strategy
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Modification Factor Call dates are determined from the following elements: - planned dates - Call Horizon - Sort Field Work Plans combine information from Task Lists and Maintenance Items, and trigger regular creation of Work Orders based on assigned Strategies via a Deadline Monitoring batch job. A Work Plan may be used to schedule work for one or more Maintenance Items. A Work Order is created for each Maintenance Item assigned to the Work Plan. Deadline Monitoring variants have been created as part of the 1SAP design. The variants call Work Orders based on the Work Plan Sort Field value. The Sort Field value should allow enough lead time to fully plan and schedule the called Work Order prior to the planned date of execution. Holding Plan Holding Plans are created for the purpose of attaching maintenance Items that are no longer required, since Maintenance Items can never be marked for deletion. Work Plans that are inactive and not flagged for deletion shall only apply to Holding Plans. All other Work Plans that are inactive shall also be flagged for deletion. A Resource Work Center is an Organisational Unit that defines who or what performs a task on a Work Order Operation. The Resource Work Center has an available capacity. The activities performed at or by the Work Center may be evaluated by Charge Rates which are determined by Cost Centers, Activity Types and Activity Price adjustment. Within Work Management, Work Centers can represent: - non human resource e.g. Crane; Workshop Machinery - groups of people responsible for Work Management Tasks - supervisors of resources within Marketing and Production Integration, Work Centers are used for various functions: - representing scheduling equipment in the planning board - representing the storage resources, Production units or Processing units - used within outbound logistics blending operations - integration of vessel sailing time for ECC (ERP Central Component) to APO (Advanced Planning and Optimization). What is a Task List? Task Lists are used as work templates, they allow repeatable Work Management tasks to be defined and then reused as required. The key features of task lists are: - internal and Long Term Resource Contractor (LTRC) labour requirements: - labour hours - duration - external labour requirements - outline agreement - service master - work procedures. General Task Lists will be used as: - generic task lists - object specific task lists. Generic Task Lists allows for: - strategy based always assigned to a Maintenance Item which is assigned to a Work Plan - non-strategy based never assigned to a Maintenance item and used as a standard job for assignment to Notifications and/or Work Orders directly. Object specific task lists only allows for:
Inactive and Deleted Work Plan What is a Work Center?
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- non-strategy based Never assigned to a Maintenance Item and used as a standard job for assignment to Notifications and/or Work Orders directly. Work Management Task Lists describe a sequence of individual resourced activities which are performed repeatedly within an Operation. Task Lists are used to standardise recurring work sequences allowing consistent, effective and efficient resource planning. Key features for the use of Task Lists are: - internal and Long Term Resource Contractor (LTRC) labour requirements - external labour requirements - materials - production, resources and tools - operation relationships - critical control indicators Task Lists will be created to support routine activities such as the following: - inspections - services - testing/calibrations - work management tasks - maintenance repairs - shutdown planning - component change outs - HSEC reporting tasks. Task Lists are used in the Budgeting process and can be pre-costed individually or via a Work Plan. What is a Shutdown Revision? A Shutdown Revision is used for identifying work which has requirements to be planned, scheduled and/or costed together. There are three types of Revisions are in Scope: - weekly - shutdown holding - shutdown event Shutdown Revisions are utilised to group Work Orders for: - a particular planned and scheduled shutdown event - costing, reporting and analysis.
Activities
Activity Description Originate Master Data Request The objective of this activity is for the learner to: - select the Work Management Objects Form - choose the Work Management Objects Form Processing Model - complete the Work Management Objects Form Details.
Component : Originate Master Data Request 405.01.01.010. Select Work Management Objects Form
Step Detail
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What
The business performs this process whenever new centralized master data is required or existing centralized master data needs to be updated. Based on the business object update required, the business selects the applicable Work Management master data request form/template for completion. All centrally maintained master data requests are submitted using master data request forms and templates within the 1SAP Portal. A form can have two states: on-line and offline. The authorized requestor maintains a connection to the 1SAP application through the 1SAP Portal with the on-line master data request form. The Data Originator is responsible for the following; - Initiate the Master Data request - Complete general information. The below form workflows to the Work Management Master Data Organisation (MDO) for Governance and Processing; - Work Management Objects Form this comprises of 10 Work Management objects (only one object may be selected at a time via the radio buttons); - Functional Location - Safety Critical Element (Equipment) - Assembly - Bill of Material - Measuring Point - Task List - Work Plan (Maintenance Plan) - Maintenance Item - WorkCenter - Shutdown Revision Note: Work Management also utilise a series of bulk load templates for the objects listed above. The templates are split by object (Safety Critical Element, Bill of Material, Task List) and action (create, change and delete). The templates are attached to the Form which in turn is attached to a Service Notification in SAP.
How
405.01.01.020. Choose Work Management Objects Form Processing Mode

Step What Detail The business initiates the master data request for the centrally maintained business object by completing the Form Scenario information such as the Action (Create, Change or Delete) and whether the scenario is for a Bulk Upload or singular Form request. This can be selected under the Form Scenario section of the guided procedure step. To generate the Master Data request the Data Originator must identify whether the request is a Create, Change or Delete activity. The Data Originator must now select the processing mode that is relevant for the request. This can be either; - a singular form request. This form has all the relevant master data fields in a list scrolling down the document and is manually loaded into SAP. This format will be used for a singular master data object request with no integration requirements - a bulk template request which captures the data requirements within a spreadsheet that is loaded into SAP. This format will be used for any master data request that requires more than one object to be processed, whether the same object or additional objects due to integration requirements. Note: The Form will route to a pre-defined Business Approver role upon submission of
How
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the Form. Workflow logic based on the combination of Form ID and Form Type will determine the Business Approver role to direct the workflow to. It is possible for the Data Originator to upload an offline PDF Form at this point. An example where this would be valid is where; - the Data Originator has recently been working on a request that they have saved locally as they have not completed the request details and now wish to add details prior to e-mailing to a Data Requestor - the Data Originator has been e-mailed an incomplete request for them to add details to prior to e-mailing to a Data Requestor. Note: the version of the Form submitted must at all times be the latest available version on the Portal. If the version of the Form submitted is not the latest available version it will fail the auto validation checks that the Data Requestor initiates online.
405.01.01.030. Complete Work Management Objects Form Details

Step What Detail The business completes the mandatory and non-mandatory fields for the master data request scenario selected on the Work Management Objects Form. Note: the Data Originator and Data Requestor can be the same person. In this case the form is not e-mailed but fully completed and then submitted to the Business Approver. The Data Originator can forward the Master Data Form to another Data Originator. The form caters for this by allowing the form to be e-mailed. An online copy of the form is not saved during this process, the original form resides as an e-mail attachment that a second Data Originator may update and submit to the Data Requestor for further detailed completion. In the instance that the Master Data Form is an offline form that has been emailed to the Data Requestor by the Data Originator, the Data Requestor will upload the form online and validate the business scenario. The Data Originator must ensure that all fields (both mandatory and non-mandatory where possible) are completed. Mandatory fields have a red border. The Description / Comments field is where the Data Originator / Data Requestor provide additional information relevant to the Master Data request to aide in review, approval and processing such as; - intent of the Master Data request - configuration requirements - testing requirements - reference to specific supporting documentation. The forms possess SAP look-up functionality (search help) via the ? button alongside certain fields. Additionally some fields have dropdown values to assist in form completion. Once the Data Originator has populated the form to the best of their ability the form can be sent to the Data Requestor via e-mail for detailed completion.
How
405.01.01.340. Select Marketing / Production Integration Work Center Form

Step Detail
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What
The business performs this process whenever new centralized master data is required or existing centralized master data needs to be updated. Based on the business object update required, the business selects the applicable Work Management master data request form/template for completion. All centrally maintained master data requests are submitted using master data request forms and templates within the 1SAP Portal. A form can have two states: on-line and offline. The authorized requestor maintains a connection to the 1SAP application through the 1SAP Portal with the on-line master data request form. The Data Originator is responsible for the following; - initiate the Master Data request - complete general information. The below form workflows to the Work Management Master Data Organisation (MDO) for Governance and Processing; - Marketing/Production Integration Work Center Form This comprises of the WorkCenter object as utilised by Marketing and Production Integration (differs from how Work Management utilise this object).
How
405.01.01.350. Choose Marketing / PI Work Center Processing Mode

Step What Detail The business initiates the master data request for the centrally maintained business object by completing the Form Scenario information such as the Action (Create, Change or Delete) and the Type (Marketing or Production Integration). This can be selected under the Form Scenario section of the Originate guided procedure step.
How
To generate the Master Data request the Data Originator must select the processing modes in the Form Scenario section of the Form. Action and Type fields are mandatory; - Action nominates if the request is a Create, Change or Delete activity - Type nominates if the Form is for Marketing or Production Integration. Note: The Form will route to a pre-defined Business Approver role upon submission of the Form. Workflow logic based on the combination of Form ID and Form Type will determine the Business Approver role to direct the workflow to. It is possible for the Data Originator to upload an offline pdf Form at this point. An example where this would be valid is where; - the Data Originator has recently been working on a request that they have saved locally as they have not completed the request details and now wish to add details prior to e-mailing to a Data Requestor - the Data Originator has been e-mailed an incomplete request for them to add details to prior to e-mailing to a Data Requestor. Note: the version of the Form submitted must at all times be the latest available version on the Portal. If the version of the Form submitted is not the latest available version it will fail the auto validation checks that the Data Requestor initiates online.
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405.01.01.360. Complete Marketing / Production Integration Work Center Form Details

Step What Detail The business completes the mandatory and non-mandatory fields for the master data request scenario selected on the Marketing/Production Integration Work Center Form. Note: the Data Originator and Data Requestor can be the same person. In this case the form is not e-mailed but fully completed and then submitted to the Business Approver. The Data Originator can forward the Master Data Form to another Data Originator. The form caters for this by allowing the form to be e-mailed. An online copy of the form is not saved during this process, the original form resides as an e-mail attachment that a second Data Originator may update and submit to the Data Requestor for further detailed completion. In the instance that the Master Data Form is an offline form that has been emailed to the Data Requestor by the Data Originator, the Data Requestor will upload the form online and validate the business scenario. How The Data Originator must ensure that all fields (both mandatory and non-mandatory where possible) are completed. Mandatory fields have a red border. The Description / Comments field is where the Data Originator / Data Requestor provide additional information relevant to the Master Data request to aide in review, approval and processing such as: - intent of the Master Data request - configuration requirements - testing requirements - reference to specific supporting documentation. The forms possess SAP look-up functionality (search help) via the ? button alongside certain fields. Additionally some fields have dropdown values to assist in form completion. Once the Data Originator has populated the form to the best of their ability the form can be sent to the Data Requestor via e-mail for detailed completion.
405.01.01.450. Select Marketing / Production Integration / Supply BOM Form

Step What Detail The business performs this process whenever new centralized master data is required or existing centralized master data needs to be updated. Based on the business object update required, the business selects the applicable Work Management master data request form/template for completion. All centrally maintained master data requests are submitted using master data request forms and templates within the 1SAP Portal. A form can have two states: on-line and offline. The authorized requestor maintains a connection to the 1SAP application through the 1SAP Portal with the on-line master data request form. The Data Originator is responsible for the following; - initiate the Master Data request - complete general information. The below form workflows to the Work Management Master Data Organisation (MDO)
How
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for Governance and Processing; - Marketing/Production Integration/Supply Bill of Material Form This comprises of the Bill of Material object as utilised by Marketing, Production Integration and Supply (differs from how Work Management utilise this object).
405.01.01.460. Choose Mkt / Prod Integration / Supply BOM Form Processing Mode
Step What Detail The business initiates the master data request for the centrally maintained business object by completing the Form Scenario information such as the Action (Create, Change or Delete) and the Type (Marketing, Production Integration or Supply). This can be selected under the Form Scenario section of the Originate guided procedure step. To generate the Master Data request the Data Originator must select the processing modes in the Form Scenario section of the Form. Action and Type fields are mandatory; - Action nominates if the request is a Create, Change or Delete activity - Type nominates if the Form is for Marketing, Production Integration or Supply. Note: The Form will route to a pre-defined Business Approver role upon submission of the Form. Workflow logic based on the combination of Form ID and Form Type will determine the Business Approver role to direct the workflow to. It is possible for the Data Originator to upload an offline PDF Form at this point. An example where this would be valid is where; - the Data Originator has recently been working on a request that they have saved locally as they have not completed the request details and now wish to add details prior to e-mailing to a Data Requestor - the Data Originator has been e-mailed an incomplete request for them to add details to prior to e-mailing to a Data Requestor. Note: the version of the Form submitted must at all times be the latest available version on the Portal. If the version of the Form submitted is not the latest available version it will fail the auto validation checks that the Data Requestor initiates online.
How
405.01.01.470. Complete Marketing / Production Integration / Supply BOM Form Details

Step What Detail The business completes the mandatory and non-mandatory fields for the master data request scenario selected on the Marketing/Production Integration/Supply Bill of Material Form. Note: The Data Originator and Data Requestor can be the same person. In this case the form is not e-mailed but fully completed and then submitted to the Business Approver. The Data Originator can forward the Master Data Form to another Data Originator. The form caters for this by allowing the form to be e-mailed. An online copy of the form is not saved during this process, the original form resides as an e-mail attachment that a
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second Data Originator may update and submit to the Data Requestor for further detailed completion. In the instance that the Master Data Form is an offline form that has been emailed to the Data Requestor by the Data Originator, the Data Requestor will upload the form online and validate the business scenario. How The Data Originator must ensure that all fields (both mandatory and non-mandatory where possible) are completed. Mandatory fields have a red border. The Description / Comments field is where the Data Originator / Data Requestor provide additional information relevant to the Master Data request to aide in review, approval and processing such as; - intent of the Master Data request - configuration requirements - testing requirements - reference to specific supporting documentation. The forms possess SAP look-up functionality (search help) via the ? button alongside certain fields. Additionally some fields have dropdown values to assist in form completion. Once the Data Originator has populated the form to the best of their ability the form can be sent to the Data Requestor via e-mail for detailed completion.
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Level 2: 405.07. Master Data Process and Quality Management

The Master Data Process and Quality Management process describes the regular activities performed to: - monitor the Master Data Request status - identify data integration, consistency and compliance issues - trigger the Master Data Management process to fix identified data integration, consistency and compliance issues.
Level 3 Processes

Key Concepts related to Master Data Process and Quality Management process are outlined in this section. Concept Why is the Master Data and Quality Management Process important to BHP Billiton? Description The intent of the Master Data Process and Quality Management process is to ensure that the Master Data Management common processes are properly tracked and the Data Integration, Uniqueness and Completeness in 1SAP is reviewed on a regular basis. This will ensure the integrity of the Master Data centrally governed (the core Master Data for BHP Billiton) across time within 1SAP.
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Overview: Master Data Process and Quality Management
This process deals with Master Data requests submitted by the data requestor. It covers the following areas: - Work Management - Supply - Finance - Marketing - HR. Amendments to Master Data (create, change, delete) can be made after the required checks are completed.
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Level 3: 405.07.01. Monitor and Track Master Data Request

Scope of Process This model describes the process for tracking the Master Data requests submitted by the Data Requestor. Business Process Objectives Data Originator, Data Requestor or Business Approval monitors the status of the master data requests submitted for approval and processing.
Process Components
Figure 1: Process Components Component Analyse Master Data Request Status Description This component details the steps involved in tracking the Master Data requests submitted by the Data Requestor.
Component : Analyse Master Data Request Status 405.07.01.060. Analyse Work Management Master Data Request Status
Step What Detail Analyse Master Data Request Status to track the Master Data requests submitted by the Data Requestor. The BI Notifications Report is refreshed every 8 hours, for a real time status report the user is able to jump to SAP transaction code IW53 (Display Service Notification) from within the BI Notifications Report. To analyse a Master Data Request status, execute the BI Notifications Report for Notification status.
How
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User Manual - Maintainer Maintenance Execution

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Maintainer Maintenance Execution User Manual

Date Generated: 28/03/2012

Component : Initiate Scope Amendment ......................................................................... 88 Level 3 Metrics ................................................................................................................ 90

Component : Create Measurement Readings................................................................ 100 Level 3 Metrics .............................................................................................................. 105

Level 3: 305.05.03. Maintain Data Quality .......................................................................................106 Activities ...........................................................................................................................................108

Component : Analyse Master Data Request Status ....................................................... 143

1SAP 1SAP User Manual Report

How to Use This Manual

What the User Manual Contains:

BHP Billiton Commercial in Confidence Date Generated: 28/49/2012

1SAP 1SAP User Manual Report

Assessments covered in this manual

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Level 1: 305. Work Management

Level 2 Main Processes

305. Work Management

305.04. Contractor Management

305.05. Data Management

305.06. Work Management Monitoring and Controlling

Figure 1: Level 2 Processes

Level 1 Process Area Concepts

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Work Management - Did You Know?

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Level 2: 305.01. Work Strategy Management

Figure 1: Level 3 Processes

Level 2 Main Process Concepts

Overview: Deploy Work Strategies

Overview: Plan Work Strategies

Overview: Execute Investigation Overview: Manage Engineering Change

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Level 3: 305.01.01. Develop Work Strategies

Define Work Strategies

Level 3 Process Concepts

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Define Work Strategy

Categories of Work Strategies

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

maintained in the same manner as per the Work Order Operations.

Component : Define Work Strategies 305.01.01.060. Define Work Strategy

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

305.01.01.070. Identify Specific Work Activities

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Level 3 Metrics Process Metrics

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012

1SAP 1SAP User Manual Report

Level 2: 305.02. Schedule Management

Figure 1: Level 3 Processes

Level 2 Main Process Concepts

Overview: Plan Work

BHP Billiton Commercial in Confidence Date Generated: 28/03/2012