76113629 SAP Plant Maintenance Overview Sourabh

SAP

Plant Maintenance Module

Overview Presented by Sourabh Sharma

Copyright 2004 Accenture All Rights Reserved.

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2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 2

2 | 21 Oct, 2004 | oSAP Program

Agenda

1. Introduction about PM

2. Structure of Organization with a view to PM

Functional Location

Equipment

BOMs

3. 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


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.


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


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.


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.



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



Technical Objects

= Functional location

= Equipment

= Bill of materials

= Material



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.



Equipment

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.



Movements of an equipment

Functional Location Functional Location

Functional Location

Equipment Equipment Equipment



Equipment vs. functional location

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



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.



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 BOMs.

Specifies only maintenance relevant components.

Maintenance BOMs 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.



Bill of material structure

Text Data Quantity Data Administrative Data General Data

BOM Header

Sub-Item

Item Category Item Status Purchasing Data

BOM Item

Functional

Location

Equipment

Material Material



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.



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



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.



Classification classes and characteristics

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



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.



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.



Catalogue structure

Object part Task

Malfunction Action

Object part Task

Malfunction Action

Object Part Causes Task

Damage Activities

Code Code 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 . . . . . .


Corrective Maintenance process

Corrective Maintenance

process



Corrective maintenance process



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.



Notification life cycle

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.


Standard Maintenance Cycle Data objects


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.


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.


Maintenance Order Structure

Elements of Maintenance Order

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)


Maintenance Order in SAP



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




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.



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.



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.



Stock material process flow

Component

assignment

Material

reservation

Order

release

Printing

Goods issue

Automatic

availability

check

Availability

check



Non-stock material process flow

Component

assignment

Purchase

application

Purchase

order

Goods receipt

Invoice receipt



PM work order release

Effects of order release:

Reservation effective, can be

withdrawn

Papers can be printed

Confirmation possible

Goods movement possible




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.



Technical order confirmation

Before the work order can be completed:

Time must be

confirmed

Goods movement

reported

Activity reports

completed

0013456998 Measurement

readings recorded



Technical completion

Effects of technical completion:

Limited ability to change order

Create settlement rule

Deletion flag for purchase requisitions

Close open reservations

Close open capacities



Reverse Technical completion

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



Order cost

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


Preventive Maintenance Preventive Maintenance


Master Data in Preventive

Maintenance

Master Data in Preventive

Maintenance



Master data objects

Plant specific master data objects:

Task list

Maintenance item

Measuring point

Global master data objects:

Maintenance strategy

Maintenance plan



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

STEPS

EQUIPMENT

LABOUR

MATERIALS

TASK LIST



e.g. strategies, maintenance planner

group, work center, equipment

e.g. strategy, Task List planner

group, main work center Task list

header

Task list Task list

header 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 Operation Operation

Maintenance

package

Maintenance Maintenance

package package

e.g. operation, time, work center,

description, control key Sub-operation Sub-operation 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 Material Material

Production

resources/tools

Production Production

resources/tools resources/tools

Maintenance task list structure



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



Preventive maintenance plan

PLAN:

Started on date Some parametres Frequency set 1m 3m 6m 1a 3a

"Maintenance strategy" A

ITEM 1

WO Header info Tasklist: A

check x

calibrate x

tune x

replace valve x

ITEM 2

WO Header info Tasklist

lubricate x

balance x



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).



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.


Preventive Maintenance process Preventive Maintenance 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.



Preventive maintenance planning framework

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 *


Refurbishment process Refurbishment 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.



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.



Questions?

Any Questions?

Thank you

76113629 SAP Plant Maintenance Overview Sourabh

Documents

maintenance planning

structuring maintenance

maintenance plants

maintenance tasks

decentralized maintenance

clarification plant

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