Sap Business Overview - Pm Module

8/10/2019 Sap Business Overview - Pm Module

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SAP PM MODULE

BUSINESS

PROCESS



The need for Information

Vision

An Integrated, Flexible and Standardised InformationSystems architecture to position towards

fundamental competitive advantage

Current Reality Function based Organisation, Multiple stand alone packages,

Time lag between market realities and decision making

SAPfor Enterprise-wide

Transformation.



SAP R/3 – The Integrated Enterprise

SAP

R/3

Client / Server

ABAP/4

FIFinancial

Accounting

COControlling

AMFixed Assets

Mgmt.

PSProjectSystem

IM

Investment Mgmt

IS-Oil

MMMaterials

Mgmt.

SD

Sales &Distribution

PPProductionPlanning

PMPlant Main-

tenance

QMQuality

Manage-ment

ECEnterpriseControlling

LDMLifecycle

Data Mgmt

CIN



Navigating SAP R/3



Navigation Topics

Logging On

SAP Window components

Using the Navigation Area

Transaction Codes

Role Based Menu

Standard Tool Bar

SAP Easy Access

User Settings

Messages

Online Help use



Logging on

Required FieldsClient

User

Password

Language



The SAP Window

Status Bar

Title Bar

Standard Tool Bar

Menu Bar

SAP System ID

Server

Insert/Overtype Indicator

Screen Header

Screen Body

Application Tool Bar

Screen Banner



Using the Navigation Area

You can expand andcollapse menus in the

navigation area by

choosing the dropdown

arrows to the left of the

menu items, as in theexample below

To open an application inthe navigation area

Double-click its node



Transaction Codes

A transaction code can be entered in the Command field.

If you precede the transaction code

with /n then the transaction is thenext screen opened in the current session.

If you precede the transaction codewith /o then a new session is openedfor the transaction. This means you then have multiple sessions.

To start a transaction in SAP 4.6, there are 4 options:

Position the cursor on the required transaction in the tree structure and pressenter

Double-click on the required transaction in the tree structure

Position the cursor on the required transaction in the tree structure and selectEdit Execute (or press F2)

Expand the command field and enter the transaction code



Standard Toolbar

The Standard Toolbar contains the Command field and the

standard SAP Toolbar buttons.

Command Field: The Command field is used to enter transaction

codes that take you directly to a system task without using

menus.

Button

Keyboard Shortcut

Description

Button

Keyboard Shortcut

Description

Enter Key

Enter/Continue

Ctrl + Page Up

First page

Ctrl + S Save to database Page Up Previous page

F3

Back

Page Down

Next page

Shift + F3

Exit System Task

Ctrl + Page Down

Last page

F12

Cancel

None

Create New session

Ctrl + P

Print

None

Create shortcut on Desktop

Ctrl + F

Find

F1

F1 Help

Ctrl + G Find next Alt + F12 Customize Local Layout



SAP Easy Access Settings

Users can set how SAP displays the Menu by choosing Extras Settings. Here,

you can specify whether:

Your favorites should appear before or after the menu

Only your favorites, and not the menu, should appear

The SAP Easy Access graphic should appear on the right-hand side of the

screen.

Technical names of menu options should appear in the navigation area

U S tti



User Settings

Users can maintain their own settings by choosing System User Profile Own

Data

Defaults

Change default printer, language, and date and decimal display formats.

Parameters

Allow user to create default information for frequently used fields.

M



Messages appear either in the status bar or in a pop-up window, depending onuser settings

Messages starting with:

“E” indicate an Error message

“W” indicate a Warning message

Messages not beginning with an “E” or a “W„‟ are simply Informationmessages

Required fields are denoted by a check mark

Messages

U i O li H l



Using Online Help

Field Level Help

Used to describe what acurrently selected field isdesigned to do.

Click on the Help icon or „F1‟.

Example:

Find definition of Material number

Click Material field

Click Help button or press F1

key

Click Cancel button to returnto the screen

SAP M il



• SAP Mail system is used to send a mail to other users of SAP in.

• The recipient is identified by User ID of SAP e.g., STR_PM3, STR-PM1,.,

• SAP Mail can be used for sending information regarding a Notification,

order, equipment etc., through SAP screen or

• through the SAP menu by tcode SBWP (Sap Business work place) for a

normal message.

Procedure :

• In a SAP screen Go to

“services for object” .

• In the following screen click on

„Send‟ icon.

SAP Mail

SAP M il



• Enter message

• If the mail is required to

be attended immediatelycheck „Express mail‟

• Enter recepient

• Click „Send‟

• or use tcode „sbwp‟ and

follow as detailed below

SAP Mail



Plant Maintenance

Overview

Section



PM-01 Organization Structure

PM-01-01 – Organization Structure

Section

Organization Structure



Organization Structure

Maintenance Planning Plant

Maintenance Plant

Aeration

BioSludge

Air Comp

System

H2SO4

Transfer

Boiler

Blowers

Functional

Locations

Organization Structuring – 1/5



Organization Structuring – 1/5

A grouping of legal,

organizational, business

and/or administrative

units with a commonpurpose. Single database

Company Code (s)

Plant (s)

Client

Maintenance Plant

Maintenance Planning

Plant

Organisation Structuring – 2/5




Represents an independent

accounting unit within a

client. Each company code

has its own balance sheetand its own profit and loss

statement.

Company Code (s)

Plant (s)

Client

Maintenance Plant

Maintenance PlanningPlant




Organisation Structuring 3/5

Operational unit withina company code.

•Material Valuation

•Inventory Management•Material Master

Company Code (s)

Plant (s)

Client

Maintenance Plant






• Maintenance Objects

• Work Centres

• Same as Plant

Company Code (s)

Plant (s)

Client

Maintenance Plant

Maintenance Planning

Plant





Planner Groups

• Task lists

• Maintenance Plans• Order Creation

• Resource Planning

• Work Scheduling

Company Code (s)

Plant (s)

Client

Maintenance Plant


Definition of the Organization Elements



Definition of the Organization Elements

Company Code: The smallest organizational unit for which a complete

self-contained set of accounts can be drawn up for purposes of external

reporting.

Maintenance Plant: Plant, in which the technical objects of a company

are installed.

The planning responsibility for a maintenance plant is defined by using

a planning plant. Maintenance plants are assigned to maintenance

planning plants.

Maintenance Planning Plant: Plant in which maintenance tasks are

planned and prepared.These tasks can relate to technical objects in

your own plant or in other plants.Maintenance planning plants are

normal plants that are indicated as maintenance planning plants in

Customizing. Maintenance plants, which do not plan their own

maintenance tasks, are assigned to the planning plants. Planning is

performed for the maintenance plants in the planning plants entered.

Section



PM-02 Master Data

PM-02-01 – Functional Location

PM Functional Location



A functional location is an element in a technical structure, representing an

area/spatial/functional of a Plant at which

Equipment/s can be installed.

Structure Indicator



Edit Mask – xxx-xxx-xxx-xxxx-xxx-xxxxx

Hierarchy levels 1 2 3 4 5 6

LEVEL 1

LEVEL 2

LEVEL 3

LEVEL 4

LEVEL5

LEVEL6

LEVEL 7

Functional Locations-Criteria



Criteria for Functional Location :

Execution of Maintenance Tasks

Recording of Maintenance Task

Data Collection over long periods of time

Cost Monitoring by Area

What affect do the Usage Condition have on thelikelihood of Damage to the installed aggregates.

Used normally for the object which are not movable.

Understanding the Transaction



g

PM-03-02-01 Master Data – Functional Location

Functional Location Structure using Tcode IH01

List Display of Functional location using Tcode IH06

Section



PM-02 Master Data

PM-02-02 – Equipment

Equipment-Criteria



Criteria of Equipments :

Management of Individual Data

Recording of Maintenance tasks

Object based recording of costs

Evaluation of technical data

Recording of Usage Times

Equipment Usage List






PM-03-02-02 Master Data – Equipments

Equipment Structure using Tcode IH03

Section



PM-02 Master Data

PM-02-03 – Measuring Points

Measuring Points



Measuring points in the R/3 System describe the physical and/or logical

locations at which a condition is described, (for example, the compressor

discharge pressure).

Measuring points are located on technical objects ie. on pieces of

equipment or functional locations.

Measuring Point can be either a parameter value or a counter.

Measurement Readings are entered for the measurement point with

reference to a specific time.

Notifications can be generated automatically if the value of the measuring

reading exceeds the range specified in measuring point.

Measurement and counter readings are stored in the system in the form

of measurement documents. These documents are the basis for

performance-based maintenance planning




PM-03-02-03 Measuring Points

Display Measuring Point using Tcode IK03

Create Measurement Document using Tcode IK11

Section



PM-02 Master Data

PM2-02-04 – Bill of Material(BOM)

Bill of material



Bill of Materials BOMs)

– A complete, formally structured list of the components making up a technical object

–The list contains the individual components together with their quantity and unit of measure

–The components can be stock or non-stock spares or assemblies

Purpose

–Material/spare parts planning

•to assign materials/spare parts to a maintenance order.

–Locating malfunctions

•to locate the malfunction in the piece of equipment or in its bill of material for a

maintenance notification.

–Material assignment

•to assign material to the individual operations of a task list.

Bill of material –

for equipment



10

Equipment - 10006767

Centrifugal Pump”

Equipment BOM

Casing type A 100-100 1 PC

PC

PC

PC

PC

PC

PC

PC

PC

30

40

50

60

70

80

90

20

Shaft

Sleeve

Bearing - A

Bearing - B

Wear Ring A

Wear Ring B

Impeller

Seal 100-300

100-400

100-500

100-600

100-700

100-800

100-900

100-200

1

1

2

1

1

4

1

2


http://images.google.com/imgres?imgurl=www.bernzomatic.com/Images/OX9.jpg&imgrefurl=http://www.bernzomatic.com/catal3.htm&h=150&w=150&prev=/images%3Fq%3Doxygen%2Bcylinder%26start%3D20%26svnum%3D10%26hl%3Den%26lr%3D%26ie%3DUTF-8%26sa%3DN



PM-03-02-04 BOM

Display Equipment BOM using Tcode IB03

Display Functional Location BOM using Tcode IB13

Section



PM-02 Master Data

PM-02-05 – General task List

Plant Maintenance task list –

Check list



THESE TASKS ARE , FOR EXAMPLE :-

• INSPECTIONS - Determining the actual condition.

• MAINTENANCE - Maintaining the ideal condition.

• REPAIRS - Restoring the ideal condition.

SEQUENCE OF INDIVIDUAL MAINTENANCE TASKS

WHICH REPEATEDLY HAVE TO BE PERFORMED ON A

MACHINE OR AT A SPECIFIC AREA.

Task List



Maintenance task lists describe a sequence of individual maintenance activities

which must be performed repeatedly within a company. The functions for

creating data in equipment task lists, functional location task lists and general

maintenance task lists are very similar and will therefore be dealt with jointly in

this section.

1. You create operations and, where necessary, sub-operations and enter detail

data for internal or external processing.

2. You can include user data in the operations or sub-operations, as required.

3.

You can assign the following objects to the operations:

Material components

Production resources/tools

Maintenance packages

Inspection characteristics You can arrange the operations according to time by

defining relationships.

You can perform a cost analysis.

Task list categories



Equipm ent 2

Equipment

Funct ional locat ion

TL

Taskl ist

categories

FL1

Op. 1

Op. 2

Op. 3

FL2

Op. 1

Op. 2

Op. 3

Op. 1

Op. 2

Op. 3

Op. 1

Op. 2

Op. 3

TL TL

Equipm ent 1

TL

General task l ists

Pumps

Op. 1

Op. 2

Op. 3

Op. 1

Op. 2

Op. 3

Cleaning

Op. 1

Op. 2

Op. 3

Op. 1

Op. 2

Op. 3

Task List Group Counter






PM-03-02-05 Task List

Display Equipment Task List using Tcode IA03

Cost Maintenance Task Lists using Tcode IA16Material Where used list: Task List using Tcode IP62

Section



PM-02 Master Data

PM-02-06 – Maintenance Plan

Types of Preventive Maintenance



2001

Performance-basedTime-based

PreventiveMaintenance

Maintenance Plans



Maintenance plan

Single cycle plan Strategy plan Multiple counter plan

Time-based Performance-based

Maintenance Plans



Maintenance Plan Functions



Scheduling Period



Scheduling data

Maintenance item

Maintenance plan

Order 901760

Cycle start Scheduling period

Schedule in future

displayed for the

specified scheduling

period

Planned dates

Orders

Scheduling period

1 year

Call Horizon




Maintenance item

Maintenance plan

Order 901760

Scheduling data

Cycle

start

Call date derived from

the call horizon Planned date

Cycle 3 months = 90 daysCall horizon at 90% = 81 days

Shift Factor




Maintenance item

Maintenance plan

Scheduling data

Cycle start

Technical completion

30/07/2003

Planned dateCycle 1 month

Shift factor 100%

Planned date

New planned date

30/07/2003(shifted by100%)

Tolerances can be used in combination with Shift factors to control theshifting of future planned dates

Cycle Modification Factor




Maintenance item

Maintenance plan

Scheduling data

Cycle start

Cycle modification

Factor

1.5

Planned date New planned date

Cycle

3 months 4.5 months

Scheduling Indicator




Scheduling Indicator

Scheduling data

Maintenance item

Maintenance plan

“Time” 1 month = 30 days

Time

Time-

key date

Time-

Factory cal.

Scheduling

indicator

“Time key date” Falls due on exactly the

same date as per the cycle

“Time Factory calendar” Falls due as per the cycle with

factory calendar as the

reference for calculating time

Cycle start

Cycle start

Cycle start

Deadline Monitoring

http://images.google.com/imgres?imgurl=www.nmgp.org/images/nut_bolt.gif&imgrefurl=http://www.nmgp.org/pages/nutsnbolts.htm&h=172&w=249&prev=/images%3Fq%3Dnut-bolt%26start%3D20%26svnum%3D10%26hl%3Den%26lr%3D%26ie%3DUTF-8%26sa%3DN



= Planned dates

Orders for the

next 90 days

Order

Deadline monitoring

Date of deadlinemonitoring run

Order 901760

Cycle 1 month



Maintenance Strategy



Package definition3 months

6 months

Maintenance Strategy

Scheduling indicatorTime

Time – using key date

Time using Fact. calendar

Strategy unitShift factors

Tolerances

Factory calendar

Scheduling Parameters




PM 03 02 06 Maintenance Plan



PM-03-02-06 Maintenance Plan

Display Maintenance Plan using Tcode IP03

Schedule Maintenance Plan using Tcode IP10Scheduling of Maintenance Plan using Tcode ZPMIP30

Maintenance Plan Cost Display using Tcode IP31

Maintenance Cycle Set using Tcode IP11Z

Add Multiple Counter Plan using Tcode IP43Maintain Maintenance Strategies using Tcode IP11

Add Strategy control Plan using Tcode IP42

Section



PM-02 Master Data

PM-02-07 – Catalogs

CATALOGS



CATALOG PROFILES

CATALOG TYPES AND

CATALOG CODE GROUPS

CODES AND DESCRIPTIONS

In PM, only the catalogs type 2,5,A,B,C is used.

Catalogs



CATALOG TYPE (B)

CATALOG PROFILE(RECIPROCATING COMPRESSOR) -1/5



CATALOG TYPE-(B)

(OBJECT PARTS)




CATALOG CODE (2)

(TASKS)




CATALOG CODE (C )

(DAMAGES)




CATALOG CODE (5)

(CAUSES)


CATALOG CODE (A)



CATALOG CODE (A)

(ACTIVITIES)


PM-03-02-07 Catalogs



g

Maintain Catalog using Tcode QS41

Section



PM-02 Master Data

PM-02-08 – Work Center

Work Centers in PM



Work center : An Organizational unit

It defines where and by whom an operation is to be performed.

Work Center in PM Module will be :

Group of Persons for eg. Multi Disciplinary team / Electrical /Mechanical / Instrumentation Team.

The work center is specified in master data of equipment or

functional location, maintenance item, task list header,

operations of task list, order header and order operations.

Work Center Contents



Work Center : Main Functions




PM-03-02-08 Work Center



Display Work Center using Tcode IR03

Section



PM-02 Master Data

PM-02-09 – Warranties

Warranties



Warranties define the scope of the services that a Vendor

should provide for a technical object in the event of damage orproblems for the validity period.

Warranties to pieces of equipment of functional locations.

Warranty in PM is :

Vendor Warrantee (for example, manufacturer or vendorwarranty)

Structure of Warranty



Warranty

header

Warranty type

Description

Classification

Warranty

items

Service activities

inclusive/exclusive

Warranty

counter Counters , limits



Section



PM-02 Master Data

PM-02-10 – Classification and Permits

Classification

Classification system uses characteristics & values to describe all

t i t d t i il i t i l



types equipment, and to group similar equipment in classes.

Classification helps in finding equipment more easily, using thecharacteristics defined in them and values as search criteria.

This also helps in finding equipment with similar or identical

characteristics.

Classification

Type Centr if ugal / Screw /Reciprocating

Capacity 50 m3/hr / 75 m3/hr / 100 m3/hr

Character istics and Values



Capacity 50 m3/hr / 75 m3/hr / 100 m3/hrRPM 975 / 1450 / 2900Head 10 M t / 20 M ts / 30 M ts

Stages 1 / 2 / 3F lu id Oil / Water / Acids

Class PUMP – Type – Capacity – RPM – Head

– Stages – Fluid

Assignment of a pump toclass pumpAssigned valuesType - Centr if ugalCapacity - 75 m3RPM - 1450Head - 10 mtStages - 1F lu id - Water

F ind a pump in Class PUMP with capacity = 75m3

Class

Maintenance Classification

Locating a pump

Permits (Technical Permits) / Process Permits




PM-03-02-10 Classification and Permits

Characteristics using Tcode CT04



Characteristics using Tcode CT04

Classes using Tcode CL02

Find objects in classes using Tcode CL30N

Maintain Permit using Tcode IPMD

Let us Get into Hands-on right now



Now, let us startunderstanding what we

discussed, better with

Hands-on Practice using

the Exercise Sheet PM-02-10.

Section



PM-03 General

Maintenance ProcessingPM-03-01 – Notification Processing

PM Notification Structure



Object Information

The Object Information contains

Structural Data, Classification



Structural Data, Classification

Data, Previous Damage, number

of days to solve the problem,Previous notification

created/completed for the

technical object, maintenance

plans and documents for the

object.






PM-03-03-01 Notification Processing Create PM Notification using Tcode IW21



Create PM Notification using Tcode IW21

Create PM Malfunction Report using Tcode IW24

Section



PM-03 General Maintenance

ProcessingPM-03-02 – Order Processing

Plant PM Planning PM Work Center

3P bl E

Damage Related Process Maintenance Flow



Technical Info.

•Breakdown

•Causes,Activities

•Object affected

PM Notification

•What

•When•Where

•Technical

Information

•Breakdown

Completion

PM History

PM Order

CompletionConfirmation

1

3

4 5

Completion

6

8

2

Problem , Error

Malfunction,Request,ActivityExecution

•Material

Withdrawals

•Utilities

•Work steps

Requesting

a Task

PM Order creationExecution plang.

•Who

•When, How long

•What work steps

•Account Assign.

•Resources

Task Planning.

7

Maintenance Processing

Notification creationPR creation

PR release as per BDP



Orderrequired ?

Order Creation

Order ExecutionMaterial withdrawal Work

Clearance/permits

Technical Completion

Order Settlement Notification Completion

Yes

No

Update technical history

Tendering, PO

creation, GR atstores and

transportation to

local storage as

per MM, OLM

procedure

PR release as per BDP

Business Completion

Maintenance Activity Types In Orders



Maintenance Order Processing

Elements of Maintenance Order

Order headerFor example: Order Type, Dates,Plant, Main object,



Order headerPriority, Description, Maintenance Activity type

Object listFor example:- Functional Locations, Equipment

Maintenance Notifications, Assemblies.

OperationFor example: Work Center, Control key, Descriptions

Standard time, Activity type,

Material list For example: Material, Quantity, Storage Location

Production resources/tools

Settlement Rule

Costs

(Estimated / Planned / Actual)

Operations

Operations



Operation Work Center Control key Description Activity Type

0010

0020

0030

0040

0050

MECH

MECH

MECH

MECH

ELEC

PM01

PM01

PM01

PM01

PM01

Oil change

Drain oil

Change oil filter

Add new oil

Check cable

List of operations

MAINT

MAINT

Stock Material Process Flow

Component

assignment



May

assignment

Material

Reservation

Order

Release

Printing

Goods

issue

May

Automatic

availability

check

Availability

check

Order Release



Reservation effective,

can be withdrawn

Shop Papers can be printed

Confirmation possible

Goods movement possible

Effects of Order Release:

Order Debits after Settlement

Other PostingsOrder Execution

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Act. Costs > 0Act. Costs > 0

• Invoice receipts

• Controlling

Postings,

• Completion

Confirmations

• Material

Withdrawals

Maintenance

Order

Order Settlement

After settlement actual

Cost on the Order is“ZERO”

Order Processing Summary

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ControllingPlant Maintenance

Order

• Order not Modifiable

• Postings can be

made to the Order

• Postings cannot

be

Made to Order

P l a n n i n g

R e l e a s e

E x e c u t i o

n

C o m p l e t i o n

C o n f i r m

a t i o n

T e c h n i c a l

C o m p l e t i o n

S e t t l e m e n t

( B u s i n e s s )

C o m p l e t i o n

Time

PM Order Costing

PM Order Costs



Internal activityOp. 10:- 3 hrs

Op. 20:- 1 hr

External processing

Op. 30:- EXTERN 1 hr .

Warehouse issue

2 pcs Material ABC

Rs. 500

Rs. 150

Rs. 300

Internal processing:-

External Services:-

Warehouse Issue:-

Total:- Rs. 950

COST CENTER

PM Order settlement



Sett lement: - Fixed Amoun t OR percentage Distr ibut ion

Equipment 4011

Operation 010: 10h

Workcenter Mech

Operation 020: 3h

Workcenter Electrical

PM Order

WorkCenter'Mech'

Work Center

Electrical

Material Receiver

Activities :-

Mech. activity.

Elect. activity.

COSTCENTRE

COST CENTER(MAINT)

Maintenance Processing Cycle



Action Logs



Order Hierarchy

If maintenance order consists of several independent steps whose

costs should be separated, order hierarchy can be used.

All b d h ld b l t d b f i d b



All sub-orders should be completed before a main order can be

completed.




PM-03-03-02 Order Processing Create PM Create Order Processing Tcode IW31(Normal)

C t PM C t O d P i T d IW31(R f bi h t)



Create PM Create Order Processing Tcode IW31(Refurbishment)

Create PM Create PM Sub Order using Tcode IW36

Goods Withdrawal using Tcode MB1A

Completion Confirmation using Tcode Tcode IW41

Overall Completion Confirmation using Tcode IW42

Section



PM-04 Refurbishment CyclePM-04-01 – Refurbishment Cycle

Refurbishment Processing

Types of Refurbishment

Refurbishment Order



Refurbishment Order

OEM Repairs Central Workshop

Refurbishment cycle - OEM

Create N9

N tifi ti

CreatePM60 type of

M i t O d

Uninstall

Equipment .



Notification Maintenance Order

Create PR/PO

q p

install at Vendors FL

Create Batch and

And send to stores with

movement type 202

Refurbishment Cycle .. contd

Send Equipment

To vendor

movement type 541

Receive Equipment (GR)

Send equipment

To Function location

Movement type 261



movement type 541

Settle & Close Order

Movement type 261

Complete Order




Create Refurbishment

OrderReplace defective parts

Complete the order.

Settle to Asset

Cost Center



To Asset

Cost Ce te

Transfer Posting from

Workshop to Asset


Send Equipment

From stores to F.

Movement type 201

Install Equipment



yp

Create

Notification

‘N9’

IH01or IW21

Maintenance

order for

repair ‘PM60’

IW31

Create a

BATCH

MSC1N

Transferring

to Stores

MB1A (202)

Refurbishment cycle for repair at OEM/External

Dismantle

equipment &

install at Repair

Location

IE02



CreatePurchase

Requisition

ME51N

Create &

release

Service entrysheet

ML81N

Change Equipment

data & Install at

original locationIE02

Stores to

Functional

locationMB1A (201)

Vendor to

Company after

repairMB1B (542)

Send to

vendor

MB1B(541)

ReleasePurchase

Requisition

ME54

Release

Purchase order

ME28

Transaction codeXXX

Create Purchase

Order

ME21N

Maintenance

order

CompletionIW32 / MIGO /

IW41 / TECO

Complete

Notification

IW22

323



Section



PM-05 Work Clearance

ManagementPM-05-01 – WCM

WCM

Reasons for Work Clearance Management : -

Maintenance Crews require safety measures.



q y

Maintenance activity need to be performed while the systems are

operational

Work related measure which require special health and safety measure

ie. Controlling and monitoring lockout and tagout of various

equipments.

WCM and Maintenance Process

WCM



WCM Architecture



The work clearance application represents the safety certificate especially forlockout/tagout.

In Plant, we will use WCA for getting prior approval to carry out any maintenance job that requires WCM.

Two types of WCA :

Hot job/Cold Job - Do not require WCD

Tagout - Requires WCD

The work clearance document describes lockout/tagout. It contains a list of the

technical objects in a technical system to be tagged or monitored. It controls thephysical blocking and signposting of the technical objects affected. It alsocontains a detailed description of how the system should be isolated.

WCM Architecture







WCM Model



WCM Permit

WCM type permit to be attached to the order for initiating WCM

WCA contains approvals to be granted for job execution



WCD contains approvals to be granted to ensure safe workingconditions.

Phases and Roles

Phases / Roles

Order Create Order Order Creator

WCM Objects Phase/Proces

s

Carried out by



Work Clearance

Appl icat ion

Work Clearance

Appl icat ion

Work Clearance

Document

Approve / Perform

Tagout

Various concerened

agencies like control

room, electrical,

mechanical, safety

Competent AuthorityApprove Work

Specify Objects

Containing TagoutOrder Creator

Application for

executing the

above orderOrder Creator

Work Clearance

Document

WCM Process

1. A Maintenance Executives (maintenance in-charge, sectional heads) creates a

maintenance Order

2. If the job requires work clearance Maintenance Executives creates the WCA for

the order and requests the approval from competent authority to perform the job.



3. He also creates / copies from a template a Work Clearance Document. The WCD

contains details the tagging/un-tagging conditions of all the equipment / functional

locations / any other object (even w/o master data) which need to be tagged to

carry out the above maintenance work.

4. WCA created above is approved by the competent authority giving the clearance

for executing the maintenance activity.

5. At the time of actual execution, the tag out / lockout of the equipment mentioned

in the WCD is approved by various concerned agencies like control room,

electrical, mechanical, safety and their status is maintained in the system.

6. Any conflict in the status of any of the specified equipment / functional location

is prompted by the system.

WCM Process

Phases / Roles

Order (after

tagging)Labour Release

Maintenance In-

charge / Executor

WCM Objects Phase/Proces

s

Carried out by



Order

Work Clearance

Document

Work Clearance

Appl icat ion

Technical complete

the orderMaintenance Incharge

Perform Un-

Tagging

Closed Approving authority

Confirm that work

in the order is

comp

Maintenance

Executive

Order

WCM Process

6. When Tagging has been performed, the maintenance In charge can release the

order ( Labor release). Order release can take place independently of this.

7. After the work has been carried out and tag-out/log-out is no longer required, the

maintenance executive sets the status Work complete for the order. Technical



completion is possible only on WCD completion.

WCA Status Sequence



WCD Structure



WCD

Enter all technical objects that are to be processed using tag-out /

logout. The WCD may include equipment, functional locations and

items not maintained in the R3 system.

Th WCD t i th d t il d d i ti f h th t h ld



The WCD contains the detailed description of how the system shouldbe isolated.

The WCD controls the physical isolation and placing of tags on

affected technical objects (items).

WCD

The WCD template is used as a copy model when creating work

clearance documents.The work clearance document template itself

cannot be used to perform lockout/tag-out. Therefore, it cannot be

tagged/untagged or assigned. With template, the work clearance

d t f l t t f t h i l t d t



documents for complex structures of technical systems do notalways have to be recreated.

The operational cycle is divided into the following operational

phases:

Tagging

Temporary un-tagging

Un-tagging

In the operational cycle, the items in an operational work clearance

document run through several statuses for each operational phase in

a specific sequence.

WCD Items



Operational Cycle



Operation Group

The WCD items defines the technical objects which need isolation for

lockout/tagout.

Operation condition gives the detailed description of conditions /

parameters for technical object (open /closed)



parameters for technical object (open /closed)

Each operation condition is valid for tagging / untagging.

Operational group is a logical grouping of operation conditions

designed to minimize the conflict.

For a technical object to be tagged / untagged, the system checks if

this objects is already a reference object in a processed Operational

WCD. A technical object cannot have different operational

conditions.

Operation Protection/Conflict Management

Protection which ensures that a technical object, which is managed as an item in an

operational work clearance document, can only be tagged/untagged from certain

Operation WCDs.

The operational protection can be used to protect the un-tagging of a position of

the operational work clearance document against other operational work clearance



the operational work clearance document against other operational work clearancedocuments.

The operational protection can be used to create protected areas. A protected area

is defined using the following criteria:

Operational protection of items in operational work clearance documents that

represent technical objects

Direct linking of operational work clearance documents using superior work

clearance applications

A technical object with operational protection can be tagged/untagged within the

protected area. However, it is not possible to tag/un-tag the technical object

outside of the protected area.

Section



PM-06 Calibration CyclePM-06-01 – Calibration Cycle

Calibration Processing Cycle

Create Measurin g Po int

Calibration

plan



Classi f icat ion

Assign to Measur ing Point List

Ass ign Measur ing

Lis t

to task List

Calibration Order

Enter Readings

Calibration Cycle

Create Measuring point of Category ‘C’ for each calibration value.

Ass ign Measurement p osi t ion fo r cal ibrat ion value.

Ass ign Measur ing Point to Task l ist .

C t i t l t t l ib t i i t d t k l i t



Create maintenance plan w rt to cal ibrat ion equipment and task l ist .

Schedu le the maintenanc e plan and release order

Enter the measurement reading fo r the equipment

Eg for a Dif f pressure f low meter with p ressure and temperatureco rrect ion s and c al ibrat ion c heck for 0,25,50,75 and 100% values, 5measur ing points for each parameter ie. total ly 15 measur ing pointexists for the meter.


PM-03-06-Calibration cycle Create measuring point IK01.

Create Measuring reading t entry list IK31.

Create Equipment task list IA01



Create Equipment task list IA01

Create measuring plan IP41

Release Order IW32.

Enter measuring reading IK34

Section



PM-07 PMISPM-07-01 – PMIS

Reporting and AnalysisMaintenance Process

PM Information system



Noti-fication

WorkOrder

Objects Downtime

CostsMTBR

Info Database

Apply

Noti-fication

Equip-ment

Info DatabaseHisto

ry

Graphic

ABC analysis

Classification

TOOLBOX

Plant Maintenance Reports

Analysis o f Maintenance Order Costs as per internal labor , material, services cost.

Monitor ing o f Maintenance ord er compl iance / back log s forPlanned / unplanned / emergency o rder.

Break down analysis as per cause damage and part fai lure



Break down analysis as per cause , damage and part fai lure.

Manufacturer w ise analysis of Equ ipment maintenance.

Mater ial Cons umption report for Equipment.

Mean time to repair and mean time between fai lure reports fo rEquipments.

Cal ibrat ion test reports for Instrum ents.

Measuring value parameters for equipment



Thank You



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