Camcode Asset Tagging Speeds Up Connectivity to Mobility Solutions

• Remediated Monroe database and found over 33% errors in naming descriptions

• Enabled Monroe to go live with a mobility solution by tagging all assets in cost effective and timely manner

• Allowed Monroe to track the cost of work at specific location, as well as the cost associated with each individual asset

Project Background

Monroe Energy was switching ERP systems from Advantis to Maximo and found they had data integrity issues in their naming descriptions. Monroe felt the data migration process would not be successful without a data collection and tagging process. Monroe determined barcodes are the foundations for mobility and standardized numbering for accurate data.

The company also wanted an unambiguous and consistent way to identify equipment for repair, which is vital in a refinery. “Maintenance is looking for one thing and operations is looking for something else,” said Steve Thomas, Maintenance/Reliability Strategist. “Time is wasted.” Monroe’s system needed unique identification for each asset within each functional group so there would be no more talking different languages. Monroe also wanted a mobile workforce utilizing Maximo and tablets.

“Maintenance is looking for one thing and operations is looking for something else. Time is wasted.”

Unfortunately, Monroe didn’t have the staff to manage this tagging and data collection process prior to going live with a mobility solution. Monroe’s main driver for choosing Camcode was the company’s experience manufacturing and installing barcode tags. Other bidders subcontracted parts which meant less control over the entire project. “At Monroe, we perceived value and flexibility by having one company control the end-to- end process,” Thomas said. “It also accelerated our mobility go live date, increasing our ROI.”

Project Implementation

Monroe’s objective was to standardize location and asset tagging of all assets by the end of 2016. This meant Camcode would gather all the data and create an individual marking specification for each asset that included the asset data, barcode type and a photo of the proposed barcode placement.

This process would create a very accurate baseline database and give Monroe a corporate marking standard for each asset. To provide a more durable and permanent identification method, Camcode used Metalphoto® tags to mark the equipment due to its 25+ year outdoor useful life. There were approximately 6,000 assets to be marked and about 8,000 tags as some assets had more than one tag.

Some assets can move or rotate, which required a separate P & ID tag and a Maximo asset tag. With fixed assets, the data could be combined on one tag.

Camcode offered Monroe customized services to help implement its barcoding project, including:

• Sending engineering teams on-site to find and identify assets, confirm data and determine the most permanent marking method.

• Engineers created a specification and marking drawing for each asset, which is now Monroe’s corporate standard for identifying each asset

• Data team configured production so tags could be produced in kits to speed up the installation process and minimize the impact on day to day operations on the refinery

• Installing all the P&ID and Maximo barcode labels in a fast and efficient manner

• Project managers oversaw this whole process and reported progress to Monroe so they could update Maximo

Project Outcomes

“At Monroe, we perceived value and flexibility by having one company control the end-to- end process. It also accelerated our mobility go live date, increasing our ROI.”

This process allowed Monroe to go live with mobility for all assets marked, gaining ROI because of the following factors:

• Monroe can track workers using tablets and reduce double tasks with work and reporting completed onsite at the asset.

• Cost of work can now be more easily and accurately associated to a specific location or asset.

• Better reliability and accountability of individual physical assets. For example, a motor would have numerous physical repairs but this could not be tracked as motors move.
• It was complicated to track cost by location when multiple assets reside there or look at costs associated with an asset that moves locations. Barcodes provide an unambiguous method for Monroe to associate Maximo information.
• The value of this project is that it allows maintenance and operations to clearly define what assets they are working on. Work order matches equipment so they know both teams are talking about the same thing.