IBM Maximo 6.2.1 Upgrade at PWCS

1. IBM Maximo 6.2.1 Upgradeat PWCS Port Waratah Coal Services Ltd Tivoli Nation July 2008 Presented by Greg Harrap Specialist Advisor Maintenance Systems

2. Agenda • Who are Port Waratah Coal Services Limited? • Why Upgrade Maximo 4.1.1 and Oracle 11.5.5? • Project Scope, Project Team and Project Timeline • Major Steps at ‘Go-Live’ • Work Still In Progress • Current Issues and Enhancements • Did the Project Achieve Our Aims? • Sample Screen-Shots • Questions?

3. What is Port Waratah Coal Services? • PWCS is the world’s largest coal export facility, with a planned throughput of 95 Million Tonnes in 2008 and a current capacity of 102 Mt, with current expansion underway for a total of 113Mt. • Most coal is destined for Japan, Korea and Taiwan for Power Generation and Steel Production.

4. Port Waratah Coal Services Ltd Pasha Bulker aground at Nobby’s Beach, Newcastle on June 8, 2007 as seen from FA-18 Hornet

5. Port Waratah Coal Services Ltd CARRINGTON KOORAGANG

6. Port Waratah Coal Services Ltd • PWCS will load coal onto around 1,000 ships in 2008 for 36 mines located in the Hunter Valley.

7. Why Upgrade Maximo 4.1.1 and Oracle 11.5.5? CAMS (Commercial and Maintenance Systems) • Maximo and Oracle were last updated in April 2002. • Support for Maximo 4.1.1 will expire in 2008. • The current version of Oracle (11.5.5) is unsupported. • The current interface does not satisfy our business needs requiring double-entry into Maximo and Oracle. • The interface was not updated when Contract Labor Reporting was introduced in 2003, making invoice matching a long, difficult task. • CAMS Upgrade is a 2007 Business Plan Task.

8. CAMS Upgrade Project – Within Scope • Maximo 6.2.1 • Oracle 11.5.10 • Maximo/Oracle Interface configuration and customisation • Invoice Matching now in Maximo • Maximo Workflows • Standard Reports re-developed • Training and documentation • MS Project – Interface

9. CAMS Upgrade Project – Out of Scope Note: these items were not included in the scope: • Maximo customisations • Oracle customisations • IT Asset Management and IT Helpdesk • Maximo data manipulation • Oracle data manipulation

10. CAMS Upgrade Project Team Project Director: Kerry Plunkett (Administration & IT Services Mgr.) Project Manager: Greg Harrap Maximo Implementer: Matrikon Pty Ltd. (Average ~2.5 persons) Oracle Implementer: ASG Group Ltd. (Average ~1.5 persons) Four Part-time PWCS Team Members representing Maintenance, Purchasing/ Stores, Finance and IT plus various other PWCS Resources as required. Actual Project Time: 4th June 2007 to 31st January 2008

11. CAMS Upgrade Project - Proposed Timeline Aim: 5 Month Implementation

12. CAMS Upgrade Project - Actual Timeline Lost 3 Key Project Resources Not All Servers Available in Final Configuration System Configured at Matrikon (Web Logix) Started using PWCS Environment (Webshpere) UAT Delayed and Being Done Whilst Training W/O Print Problems

13. Major Steps at Go-Live Dec 2007 – In V4.1.1, finalise all outstanding Labor Reporting Transactions. Close out outstanding Purchase Orders and clean up data for upgrade. Cut-off Interface for EOM/EOY. Jan 2 –Maximo outage (8 hrs) for migration to V6 on MAXP Database. Jan 2-11 – Complete EOM/EOY processing in Old Oracle. Jan 11-13 – Oracle Outage (3 days) to allow migration to New Oracle on CAMP Database. Jan 14 – Maximo outage (4 hrs) to merge Maximo V6 with Oracle on CAMP Database.

14. Work In Progress • Testing of Maximo Patch 6.2.2 • to resolve issues/bugs • Resolution of remaining implementation issues • Details to follow • Automatic ordering of catalogued contract items • Supply Group improvement work • Automatic payment generation upon receipt of key inventory supplies • Will start with Blackwoods • Invoice processing for the single Blackwood’s invoice each month is around 2 hours • Process has already identified items in stock currently not under Blackwood’s contract (~100 items)

15. Current Implementation Issues • 14 Issues remain outstanding • Key issues are: • Printing W/Os – large batches with attachments – major issue • Screen freeze in some apps when no data returned • Unable to cancel some PRs (Resolved in V6.2.2) • Can’t use search options in Self Service Requisitions (maybe an introduced bug)

16. Current Enhancements • 16 Enhancement requests are being processed. Each enhancement is reviewed and costed for a cost/benefit analysis. • Enhancements include: • Establishing Service Request Workflow (being tested) • Automating creation of Labour Invoices at EOM • Warning of high value Labour when entered (done) • Limiting PO over-receipting to $20 (done) • Establish Purchase Agent on PR and carry it across to the PO (being testing) • Identify Repairable stock to exclude from automatic stock re-order (done) • Escalation to update PM task work orders when the parent work order is re-scheduled.

17. Did We Achieve Our Aims: Upgrade Benefits: • Ensure key business systems are fully supported. • Eliminate double-handling of data by improving the interface. • Reduce the amount of data entry by using Maximo Workflow. • Improve Work Management, provided with new functionality in Maximo V6.2.1. • Improve communications without additional effort.

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22. Port Waratah Coal Service Ltd Questions? Email: Greg.Harrap@pwcs.com.au