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Home Communications In the News Maximo Barcoding: Where Has it Been All Our Lives?

4.30.2019

Maximo Barcoding: Where Has it Been All Our Lives?

by Megan Matthews, Project Engineer, CMMS Services at NAES Corporation

Every plant staff I visit has a list of improvements they want to see in their CMMS system. For most of them, barcode scanning for inventory ranks in their top five. The promises of barcode scanning are appealing, to say the least: no more issues with lost inventory; less time checking out the inventory items; quicker cycle counts; and the list goes on. You can make barcoding a reality – but only with a lot of work up front as well as ongoing maintenance of your inventory program. I’ll describe here the tools you’ll need, the benefits to be had, and also the pitfalls you may encounter in working with your barcoding software.

According to IBM, every barcoding system needs a scanner. A cell phone is not set up to scan barcodes and lacks the speed and accuracy required by your system. However, a Bluetooth scanner attached to your phone, tablet or laptop will work. These devices range from $550 to $700, and it’s a good idea to acquire at least two of them for your site.

Your Maximo 7.6 software has the capability to use mobile devices, but they don’t have the capability to use the barcode scanner out of the box. You do, however, have several options available for integrating Maximo with your scanner. First, there’s Maximo Anywhere, a Maximo application that allows you to use scanners, edit and create work orders, check out inventory when offline, and  seamlessly upload any changes to Maximo when you are back on site. The second option is to go with a third-party software, several of which are available at additional cost for both the software itself and the implementation. We even have a mobile solution currently in development here at NAES.

You’ll find that your barcode scanner has many uses. You can charge inventory to a work order by assigning a barcode to both the work order and the inventory. You can receive inventory and quickly scan it into the correct bin location. You can easily count inventory by scanning the item and entering the number of units in the bin. You can assign a barcode to each asset so that any technician who sees an issue in the field can scan the asset to create a work order for it. They can also pull up a listing of inventory spares by scanning the asset, which makes it easier for them to identify the inventory required for the work order. You can also assign barcodes to work orders, so that technicians in the field can scan their work list barcodes to get details about the task at hand or open the work order to apply their labor hours.

Maximo Barcoding Image

In addition, scanners can help you improve your work processes and reduce the workload on your inventory and purchasing staff. When technicians scan out their own inventory for their jobs, it

increases the accuracy of your inventory counts. This allows you to cut costs by maintaining a leaner set of inventory stock, reduce warehouse space requirements, and avoid inventory shortages and the ensuing work slowdowns. Your warehouse staff will spend less time on data entry, ensure that they’ve ordered necessary inventory, that it’s processed efficiently and properly labeled and stocked for future use.

Now that you’ve read about all the benefits of barcode scanning, you may already be creating a PR for your purchase. However, you need to have a few things in place before you can use scanners at your plant. First, you need to have an efficient means of creating work orders on the weekends and evenings. If your staff are unable to assign an inventory item to a work order during all shifts, they won’t be able to utilize the system, in which case your warehouse manager won’t see any benefit from the new scanning system.
Second, you must have your inventory set up correctly, as follows:

  • Indicate which items are to be stocked
  • Set a minimum and maximum inventory balance for each item
  • Assign items to appropriate bins and update the default bins
  • Ensure that all inventory items are properly barcoded, that the barcode is easy to find and scan

If you’re using inventory and assets to find spare parts, make sure your inventory is assigned to appropriate assets – or that it is automatically added as a spare part when used on a work order for a specific asset. Lastly, you must be able to continually create and apply barcodes to new items. This requires a fully trained warehouse manager as well as ongoing training for employees on proper use of the system.

If you’d like to know more about barcode scanning, need advice on software or hardware (I promise we’ll give you options) or have other questions about Maximo, please email our CMMS team or contact your NAES CMMS representative.

 

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    CAISO Generator Modeling Process and Data Requirements

    Don’t wait until the last minute. You should allow time for at least one iteration with CAISO so that you are complete and deemed compliant before your deadline.

    On August 1, 2018, CAISO introduced a revised Business Practice Manual for Transmission Planning Process (BPM), which includes new data requirements for interconnected generation resources within the ISO’s footprint. Section 10 of the BPM establishes revised data requirements and compliance procedures for all participating generators including non-NERC registered entities. While additional requirements have been placed on larger NERC registered facilities, these changes may pose an even greater burden to entities that have been exempt from NERC mandated modeling and protection requirements.

    New data requirements include voltage and frequency protection models, power flow models, and in some cases, sub-synchronous resonance models. These models must be verified using criteria listed in the BPM, which can only be performed by entities with modeling software and knowledge of modeling practices.

    NAES is prepared to assist entities with data aggregation, modeling, and testing to ensure compliance with CAISO’s data requests. The following links will allow entities to determine when to expect their individual data requests (phase) and what data will be required (category).

    Business Practice Manual (BPM)

    Entity Category and Phase Listing

    CAISO Transmission Planning Website

    TPL-007

    TPL-007 establishes planning criteria for induced currents caused by geomagnetic disturbances. The standard is applicable to facilities using transformer(s) with a high side, wye grounded winding operated above 200 kV and can require both submittal of general geomagnetic data (R2) and thermal impact assessments (R6) depending on results of Planning Coordinator analysis.

    VOLTAGE AND REACTIVE (VAR) STANDARDS

    VAR-501-WECC

    VAR-501-WECC requires applicable entities within the WECC region to confirm performance settings and characteristics of Power System Stabilizers (PSS). NAES provides physical testing and reporting services to address WECC’s specific PSS requirements.

    PERSONNEL PERFORMANCE, TRAINING AND QUALIFICATIONS

    PER-006

    PER-006 requires Generator Operators to provide training to personnel who are responsible for the Real-time control of a generator. NAES has developed specific protection system training materials suitable for compliance with the Standard and provides this training both on and off site

    PROTECTION AND CONTROL (PRC) STANDARDS

    PRC-001

    PRC-001 requires entities to coordinate protection system changes with other affected parties. NAES offers both procedural documentation and engineering services to establish the required coordination for both PRC-001 and PRC-027.

    PRC-002

    PRC-002 requires the installation and operation of disturbance monitoring equipment (DME) for applicable entities. NAES can assist with the design and installation of DME as well as ongoing compliance support.

    PRC-019

    PRC-019 requires applicable entities to show coordination between voltage regulating controls, limiters, equipment capabilities, and protection settings. NAES produces PRC-019 specific coordination studies for both traditional generators and renewable projects to establish compliance with the Standard.

    PRC-023

    PRC-023 requires load responsive protective relays be set according to criteria within the Standard to ensure settings do not limit transmission loadability. NAES provides full engineering analyses to maintain compliance with this Standard.

    PRC-024

    PRC-024 requires applicable entities to ensure generator protective relays do not trip within predefined frequency and voltage limits. NAES can complete protection settings analyses and provide compliance documentation that clearly identifies protection settings as they relate to NERC’s “no trip” zones.

    PRC-025

    PRC-025 establishes minimum settings requirements for load-responsive relays protecting generators, step up transformers, and auxiliary transformers. NAES utilizes predefined calculation options as well as simulations to determine a facility’s compliance status and development of new relay settings if required.

    PRC-026

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    MODELING, DATA, AND ANALYSIS (MOD) STANDARDS

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    MOD-026

    MOD-026 requires verification of excitation or volt/var control dynamic models through utilization of either system disturbances or physical testing. NAES offers full testing and modeling services to meet the requirements of this standard.

    MOD-027

    MOD-027 requires verification of governor or active power/frequency control dynamic models through utilization of either system disturbances or physical testing. NAES offers full testing and modeling services to meet the requirements of this standard.