BHP WAIO Rail Workshop
Mooka Ore Car Repair Shop
Supporting asset information development, BOM creation, reliability improvement and long-term maintenance support for a mature automated workshop environment.
Challenge
The Mooka Ore Car Repair Shop had been operating for approximately 12 years (in 2026) and had reached a stage where equipment reliability was becoming increasingly dependent on the availability of accurate maintenance information, spare parts data and asset master data.
Despite being a highly automated facility, many critical assets did not have complete Bills of Materials (BOMs) established within SAP. As equipment matured, component failures were becoming more frequent and maintenance teams faced increasing challenges identifying spare parts requirements, managing component obsolescence and addressing manufacturer part number changes.
The absence of structured BOMs within SAP increased the risk of extended downtime, delayed repairs, inefficient spare parts management and reduced confidence in long-term asset support strategies.
Approach
- SAP PM Bill of Materials (BOM) development
- Detailed review of vendor manuals and technical documentation
- Engineering drawing analysis and asset verification
- Field verification of installed equipment
- Asset information validation and structuring
- Material identification and cataloguing
- Repairable item master data improvement
- Component identification and mapping
- Obsolescence review and management support
- Manufacturer part number reconciliation
- Master data quality improvement
- Maintenance planning support
BOM structures were developed through the review of vendor documentation, engineering drawings and field verification activities to ensure maintenance and materials information accurately reflected installed equipment.
Repairable item master data was also reviewed and updated to improve asset traceability, repair management and long-term maintenance support strategies.
Outcome
- Developed structured Bills of Materials within SAP
- Improved visibility of critical asset components and spare parts requirements
- Enhanced maintenance planning capability
- Improved material identification and procurement support
- Improved repairable item master data quality and traceability
- Improved management of component obsolescence
- Improved management of manufacturer part number changes
- Reduced asset information risk associated with aging equipment
- Strengthened long-term asset support capability
Key Capabilities Demonstrated
Project delivery undertaken in collaboration with M1 Solutions.