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SAP �Plant Maintenance Module Overview�Presented by Sourabh Sharma

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Agenda

Introduction about PM
Structure of Organization with a view to PM

Functional Location
Equipment
BOMs

Type of maintenance

Corrective maintenance

Master data in corrective maintenance

Corrective maintenance process

Preventive maintenance

Master data in preventive maintenance

Preventive maintenance process

Refurbishment

Refurbishment process

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Introduction to Plant Maintenance

What?

Planning, processing and documenting of repair tasks for corporate operation and production resources.

Why?

To maintain the various resources of plants in order to ensure the smooth and efficient working.

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Activities under Plant Maintenance :

Inspection

All measures which establish the actual condition of a technical system

Preventive maintenance

All measures which maintain the ideal condition of a technical system

Repair / Breakdown Maintenance

All measures which restore the ideal condition of a technical system

Maintenance Projects

All Measures required to make modifications or add to existing technical system

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Planning Organization Structuring

Centralized Maintenance Planning

The company has several maintenance plants, however, only one plant in which maintenance planning is performed.

Decentralized Maintenance Planning

The company comprises several maintenance plants. Each plant performs its own maintenance planning.

Partially Centralized Maintenance Planning

The company comprises several maintenance plants. Some of the maintenance plants perform their own maintenance planning, others do centrally.

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Structuring

Maintenance Plant

The maintenance plant for a technical object is the plant at which it is installed
E.g. Clarification plant C1 is located in plant 0001. Plant 0001 is therefore the maintenance plant for the clarification plant C1.

Maintenance Planning Plant

The maintenance planning plant for a technical object is the plant in which the maintenance tasks for the object are planned and prepared .
E.g. The maintenance plant for the clarification plant C1 is plant 0001. Plant 0001 does not perform its own maintenance planning. It is assigned to plant 0002 . The maintenance planning plant for the clarification plant C1 is therefore plant 0002.

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Master data objects

Plant specific master data objects:

Work center

Functional location

Equipment

Assembly

Bill of material

Document and links

Object network

Global master data objects:

Material master

Classification classes and characteristics

Catalogues

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Technical Objects

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= Functional location

= Equipment

= Bill of materials

= Material

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Functional location

Is a multi-level hierarchical breakdown structure of machinery. Individual equipments can be installed within this hierarchy.

Provides a context for executing and recording maintenance tasks.

Provides a framework to monitor and track costs.

Provides a framework to monitor and track location of equipments.

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Equipment

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Equipment is a uniquely identifiable physical machine, upon which work can be carried out and about which costs and history can be recorded.
More than one piece of equipment can be installed at a functional location.

Equipment should be created if:

Individual data is to be managed for the object (for example, year of construction, warranty period, usage sites).
A record of the maintenance tasks performed for the object must be kept (e.g. for insurance or legal inspection purposes).
Technical data on the object is to be collected and evaluated over a long period of time.
The costs of maintenance tasks are to be monitored for the object.
Records of usage times at functional locations are required for the object.
Documents and BOM follow an equipment irrespective of installation location.

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Movements of an equipment

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Functional Location

Equipment

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Equipment vs. functional location

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Technical object	Functional location	Equipment
	This is relatively stable, may not be changed in years	This is laid into a certain position and it can be changed more often
Example	Turbine	Motor Oil pump Shaft

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Equipment design

If the object at a functional location will never move physically, such as a storage tank, it is not necessary to set up an equipment record. Any work can be raised against the related functional location.

Determine movable and non-movable machines to see whether an equipment needs to be created or not.

Equipment can be installed on or dismantled from either a superior equipment or a functional location.

Equipment needs to be installed on the correct functional location during conversion.

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Bill of material

A maintenance Bill Of Material (BOM) is a structured list of the components (i.e. functional location or equipment) or an assembly (material).

The BOM contains object numbers of individual components together with their quantity and unit of measure. The components can be Stock or Non-Stock Spares or Assemblies, which in turn can be described using maintenance BOM’s.

Specifies only maintenance relevant components.

Maintenance BOM’s are primarily used for the following purposes:

Structure description

A maintenance BOM describes the structure of a technical object or material. Using maintenance BOM you can specify exactly where maintenance tasks are to be performed on a Technical Object.

Assignment of spare parts

A maintenance BOM is used in PM to assign spares for a technical object for documenting and choosing materials.

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Bill of material structure

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Text Data

Quantity Data

Administrative Data

General Data

BOM Header

Sub-Item

•

Item Category

•

Item Status

•

Purchasing Data

BOM Item

Functional

Location

Equipment

Material

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Bill of material design

Use of generic BOMs (i.e. Material BOMs) rather then specific functional location or equipment BOMs.

Material BOM - A generic BOM is applicable to one or many equipments or functional locations. By using generic material BOMs, maintenance is simpler since there are less BOMs.

Spare Parts will be in SAP as part of the BOM.

Material need to be defined before the BOM can be built.

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Document and links

Offers document references and an easy access to related documents for

functional locations,

equipments and

machine models (materials).

Access within master data, notifications and work orders.

Requires organized servers and folder structures

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Material master

Maintenance relevant materials are for example:

spare parts

assemblies

common machines

All data of a material is integrated in one master record.

Integration also enables the master data to be used jointly by purchasing and other areas like inventory management and invoice verification.

In maintenance processing materials are used e.g. in ordering and reserving spare parts.

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Classification classes and characteristics

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Characteristics

An attribute describing an object

1. Create characteristics

Class

A group of objects that has the same or similar properties

2. Create a class

Object

A classifiable unit

3. Link the class to an object

Characteristics value

Acceptable values of a characteristic

4. Assign values for characteristics

Pump capacity, Pressure

Pumps, Electric motors

Equipment, Functional location

Pump capacity: 2000 l/s, Pressure: 1,6 MPa

Description

Example

Method

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Catalogues

Maintenance catalogues are groups of standardized codes used to report technical history for work that has been performed.

There are various types of catalogues that can be defined in SAP. Typical ones are:

Object part catalogue allow the user to specify the specific part of a piece of equipment or functional location that work is being requested or performed for.

Fault code catalogue allow the user to specify the type of damage that has been observed.

Cause code catalogue allow the user to specify the root cause.

Activity code catalogue allow the user to specify what activities were carried out to fulfill a work request or to document work that was carried out.

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Catalogues

Technical history associated with the repair and maintenance of specified equipment provides a basis for monitoring plant and equipment integrity, such as:

Frequency of failure

Failure grouping and analysis

Impacts of maintenance strategies (planned Maintenance, corrective maintenance, run to failure)

Component reliability analysis

Support to report analysis

Standardized codes enable benchmarking.

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Catalogue structure

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Object part

Task

Malfunction

Action

Object part

Task

Malfunction

Action

Object Part

Causes

Task

Damage

Activities

Code

Code-

group

Code-

group

Code-

group

Catalogues for:

Catalogue Structure:

Example

:

Catalogue

Code Group

Code

Malfunction

Catalogue

Mechanical

Malfunction

Code

010

Corrosion

020

Broken Glass

030

Defect Engine

.

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Corrective Maintenance process

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Corrective maintenance process

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Description of the process

The corrective maintenance planning process

Starts with creation of notification,

either a fault report

or a maintenance request,

ends with the creation of a maintenance work order,

includes several decision points whether to

create maintenance work order,

postpone to later or

cancel request.

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Notification life cycle

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Notification

creation

Notification

review

Postpone/

cancel/

continue

Put in process

Assign to

order

Notification is created to report a fault or request for maintenance

Notification in the system can be reviewed and updated

When notifications are reviewed, a decision is made whether to continue with the notification immediately, to postpone it until later or to cancel it

When decision has been made to continue with the notification, it will be put in process.

Once the notification is put in process it can be assign to a work order

Complete

notification

After the completion of the notification, it is no longer possible to change / update it.

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Standard Maintenance Cycle – Data objects

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Maintenance Order

What is a Maintenance Order ?

It is a detailed planning of the maintenance task which has to be performed.

Why Maintenance Order ?

Plan tasks in detail with regard to type, scope, dates and resources.
Monitor the execution of tasks.
Define rules for account assignment, settlement and budgets.
Enter, assign and settle the costs which arise from tasks.

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Information from the Maint. Order

Location or Equipment needing the repair ( inherited from the Notification data).
List of activities to be performed and estimated completion times.
Maintenance resource(s) to perform the activities.
Spares required for the repair.
Cost of the repair jobs carried – Planned & Actual.
Where the costs of the order would be settled.

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Maintenance Order Structure

Elements of Maintenance Order

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Order header

For example: Order Type, Dates,Plant, Main object,� Priority, Description, Maintenance Activity type

Object list

For example:- Functional Locations, Equipment� Maintenance Notifications, Assemblies.

Operation

For example: Work Centre, Control key, Descriptions� Standard time, Activity type,

Material list

For example: Material, Quantity, Storage Location

Production resources/tools

Settlement Rule

Costs

(Estimated / Planned / Actual)

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Maintenance Order in SAP

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Notification vs. PM work order

Notification

Technical object

Classes

damage

cause

Activity history

No costs

Work order

Object list

Operations

work center

material

quantity

resources

Settlement rules

Costs

estimated

planned

actual

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Description of the process

Work order planning and scheduling

Starts after the maintenance work order has been created and finishes when the work order is scheduled to execution.

The process includes planning of material

stock material from the warehouse

non-stocked material to be purchased for the order

and planning of resources

own resources

external services to be purchased.

The scheduling part co-ordinates timing of work orders.

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PM work order system status

System status

Automatically created

Shows actions taken or not taken

The work order can have several system statuses

Ex:

CRTD, order created

MANC, material availability not checked

PRC, precosted

PRT, work order printed

REL, work order released

PCNF, work order partially confirmed

TECO, work order technically completed.

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External services

External services will be processed in two different ways:

Frequently used contractor with a long time contract

Processed using an internal work order with an external work center.

Sporadically used contractor

Processed using purchase requisition and material master.

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Stock material process flow

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Component

assignment

Material

reservation

Order

release

Printing

Goods issue

Automatic availability check

Availability

check

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Non-stock material process flow

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Component

assignment

Purchase

application

Purchase

order

Goods receipt

Invoice receipt

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PM work order release

Effects of order release:

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Reservation effective, can be withdrawn

Papers can be printed

Confirmation possible

Goods movement possible

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Description of the process

Work order execution

Starts when the work order has been released for execution,

ends when the work has been completed and the costs are settled,

includes

material issue,

execution of the work,

time reporting,

updating notification,

updating technical object and

cost settlement.

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Technical order confirmation

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Before the work order can be completed:

Time must be confirmed

Goods movement reported

Activity reports completed

0013456998

Measurement readings recorded

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Technical completion

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Effects of technical completion:

Limited ability to change order

Create settlement rule

Deletion flag for purchase requisitions

Close open reservations

Close open capacities

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Reverse Technical completion

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Effects of reverse technical completion:

Order becomes modifiable again

Status REL is set

Locations and account assignment data are recopied from the object

Open purchase requisitions are recompiled

Open reservations are recompiled

Open capacities are recompiled

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Order cost

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Estimated costs are entered at order creation

Planned cost are calculated at order planning

Actual costs are calculated at material issue and time confirmation

All costs can be viewed on work order

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Preventive Maintenance

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Master Data in Preventive Maintenance

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Master data objects

Plant specific master data objects:

Task list

Maintenance item

Measuring point

Global master data objects:

Maintenance strategy

Maintenance plan

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What is a task list

Describes a sequence of individual operations which have to be completed

Related to a functional location and equipment

Types of task list

General task lists are maintenance tasks lists - sequence of tasks defined and managed centrally and used for scheduling work on multiple equipments/sites

Object specific task lists are specific to functional locations or equipment

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STEPS

EQUIPMENT

LABOUR

MATERIALS

TASK LIST

………………………………………………………………………………………………………………………………………………………………………

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Maintenance task list structure

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e.g. strategies, maintenance planner

group, work center, equipment

e.g. strategy, Task List planner

group, main work center

Task list

header

Task list

header

e.g. Frequency

e.g. work center, description, time

control key, external processing data,

maintenance packages

e.g. work center, description, timing,

control key e.g. external service

Operation

Maintenance

package

Maintenance

package

e.g. operation, time, work center,

description, control key

Sub-operation

e.g. quantities, BOM items,

item category, unit of measure

e.g. Material Numbers quantities, BOM items,

unit of measure

e.g. amount, type

e.g. Mobile Crane

Material

Production

resources/tools

Production

resources/tools

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Preventive maintenance strategy

A maintenance strategy is a set of defined frequencies or packages with scheduling parameters assigned to them

Time based maintenance strategy samples:

Weekly

Monthly

3 Monthly

Yearly

Counter based maintenance strategy samples:

Hours run

Liquid pumped out

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Preventive maintenance plan

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Measuring point

Are used to enter measurements and counter readings (quantitative operating data) for technical objects.

Measuring point is a physical and/or conceptual location at which a condition is described.

Accumulated totals can trigger a PM Notification or PM Order.

Typical situations of use are:

Counter-based maintenance (preventive maintenance every 1000 production hours).

Condition-based maintenance (preventive maintenance when brake pad minimum thickness has been reached).

Condition of the object is needed to be documented at a particular point of time (e.g. legal, health and safety reasons).

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Measuring point

Measurements and counter readings are represented in SAP as measurement documents.

Measurement and counter reading data can be entered into SAP e.g.:

Manually using SAP user interface.

Manually using browser and transferring it to SAP via Internet.

Semi-automatically using barcode reader and transferring it from external system to SAP via interface.

Automatically transferring it from external system to SAP via interface.

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Preventive Maintenance process

Preventive Maintenance Process

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Description of the process

Normal PM preventive maintenance process

Starts with the creation of a maintenance strategy.

Ends with automatic generation of work orders.

Includes maintenance task lists, plan creation and maintenance plan scheduling.

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Preventive maintenance planning framework

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1M * 1000 H

2M * 8000 H

3M * 10000 H

etc.

Service Master

Strategy

Maintenance Plan

Package

Material Master

Vendor /Contract

Operation

Call Object /Work Order

Standard Text

Sub Operation

Object List

Maintenance Item

Task List

Counter *

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Refurbishment process

Refurbishment Process

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Description of the process

Refurbishment

The refurbishment process starts with creation of a refurbishment work order for a material number and

ends with completion of the work order.

Planning and scheduling of the refurbishment work order follows the normal planning and scheduling process flow.

After the refurbishment work has been executed the refurbished material may be put to stock.

For refurbished equipment the status is changed.

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Additional details

Refurbishment cases can be handled in different ways:

Equipment with normal PM work order, where equipment does not have SAP serial number. These are major machines.

Smaller machines and major components with refurbishment work order. These have normal material number with split valuation and possibly a serial number.

Smaller low value components with standing work order and zero stock value.

Before the equipment is refurbished, its status will be changed to waiting to be refurbished.

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Questions?

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Any Questions?

Thank you