SAP Plant Maintenance Module Overview Presented by Sourabh Sharma Copyright © 2004 Accenture All Rights Reserved. Accenture, its logo, and High Performance Delivered are trademarks of Accenture.
Dec 03, 2014
SAP Plant Maintenance Module
OverviewPresented by Sourabh Sharma
Copyright © 2004 Accenture All Rights Reserved. Accenture, its logo, and High Performance Delivered are trademarks of Accenture.
Copyright © 2010 Accenture All Rights Reserved. 2© 2004 Accenture All Rights Reserved.
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
Copyright © 2010 Accenture All Rights Reserved. 3© 2004 Accenture All Rights Reserved.
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.
Copyright © 2010 Accenture All Rights Reserved. 4© 2004 Accenture All Rights Reserved.
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
Copyright © 2010 Accenture All Rights Reserved. 5© 2004 Accenture All Rights Reserved.
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.
Copyright © 2010 Accenture All Rights Reserved. 6© 2004 Accenture All Rights Reserved.
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.
Copyright © 2010 Accenture All Rights Reserved. 7© 2004 Accenture All Rights Reserved.
7 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 8© 2004 Accenture All Rights Reserved.
8 | 21 Oct, 2004 | oSAP Program
Technical Objects
= Functional location
= Equipment
= Bill of materials
= Material
Copyright © 2010 Accenture All Rights Reserved. 9© 2004 Accenture All Rights Reserved.
9 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 10© 2004 Accenture All Rights Reserved.
10 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 11© 2004 Accenture All Rights Reserved.
11 | 21 Oct, 2004 | oSAP Program
Movements of an equipment
Functional Location Functional Location
Functional Location
Equipment Equipment Equipment
Copyright © 2010 Accenture All Rights Reserved. 12© 2004 Accenture All Rights Reserved.
12 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 13© 2004 Accenture All Rights Reserved.
13 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 14© 2004 Accenture All Rights Reserved.
14 | 21 Oct, 2004 | oSAP Program
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 descriptionA 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 partsA maintenance BOM is used in PM to assign spares for a technical object for
documenting and choosing materials.
Copyright © 2010 Accenture All Rights Reserved. 15© 2004 Accenture All Rights Reserved.
15 | 21 Oct, 2004 | oSAP Program
Bill of material structure
Text Data Quantity Data Administrative Data General Data
BOM Header
Sub-Item
• Item Category• Item Status• Purchasing Data
BOM Item
FunctionalLocation
Equipment
MaterialMaterial
Copyright © 2010 Accenture All Rights Reserved. 16© 2004 Accenture All Rights Reserved.
16 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 17© 2004 Accenture All Rights Reserved.
17 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 18© 2004 Accenture All Rights Reserved.
18 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 19© 2004 Accenture All Rights Reserved.
19 | 21 Oct, 2004 | oSAP Program
Classification classes and characteristics
CharacteristicsAn attribute describing an object
1. Create characteristics
ClassA group of objects that has the same or similar properties
2. Create a class
Object A classifiable unit3. 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
Copyright © 2010 Accenture All Rights Reserved. 20© 2004 Accenture All Rights Reserved.
20 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 21© 2004 Accenture All Rights Reserved.
21 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 22© 2004 Accenture All Rights Reserved.
22 | 21 Oct, 2004 | oSAP Program
Catalogue structure
Object part Task
Malfunction Action
Object part Task
Malfunction Action
Object Part Causes Task
Damage Activities
CodeCodeCode
Code-groupCode-
groupCode-
group
Catalogues for:
Catalogue Structure: Example :
Catalogue
Code Group
Code
MalfunctionCatalogue
MechanicalMalfunction
Code010 Corrosion020 Broken Glass030 Defect Engine. .. .. .
Copyright © 2010 Accenture All Rights Reserved. 23© 2004 Accenture All Rights Reserved.
Corrective Maintenance processCorrective Maintenance
process
Copyright © 2010 Accenture All Rights Reserved. 24© 2004 Accenture All Rights Reserved.
24 | 21 Oct, 2004 | oSAP Program
Corrective maintenance process
Copyright © 2010 Accenture All Rights Reserved. 25© 2004 Accenture All Rights Reserved.
25 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 26© 2004 Accenture All Rights Reserved.
26 | 21 Oct, 2004 | oSAP Program
Notification life cycle
Notification creation
Notification review
Postpone/cancel/
continuePut 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.
Copyright © 2010 Accenture All Rights Reserved. 27© 2004 Accenture All Rights Reserved.
Standard Maintenance Cycle – Data objects
Copyright © 2010 Accenture All Rights Reserved. 28© 2004 Accenture All Rights Reserved.
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.
Copyright © 2010 Accenture All Rights Reserved. 29© 2004 Accenture All Rights Reserved.
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.
Copyright © 2010 Accenture All Rights Reserved. 30© 2004 Accenture All Rights Reserved.
Maintenance Order Structure
Elements of Maintenance Order
Order headerOrder header For example: Order Type, Dates,Plant, Main object,Priority, Description, Maintenance Activity type
For example: Order Type, Dates,Plant, Main object,Priority, Description, Maintenance Activity type
Object listObject list For example:- Functional Locations, Equipment Maintenance Notifications, Assemblies.
For example:- Functional Locations, Equipment Maintenance Notifications, Assemblies.
OperationOperation For example: Work Centre, Control key, DescriptionsStandard time, Activity type,
For example: Work Centre, Control key, DescriptionsStandard time, Activity type,
Material listMaterial list For example: Material, Quantity, Storage LocationFor example: Material, Quantity, Storage Location
Production resources/toolsProduction resources/tools
Settlement RuleSettlement Rule
Costs(Estimated / Planned / Actual)
Costs(Estimated / Planned / Actual)
Copyright © 2010 Accenture All Rights Reserved. 31© 2004 Accenture All Rights Reserved.
Maintenance Order in SAP
Copyright © 2010 Accenture All Rights Reserved. 32© 2004 Accenture All Rights Reserved.
32 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 33© 2004 Accenture All Rights Reserved.
33 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 34© 2004 Accenture All Rights Reserved.
34 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 35© 2004 Accenture All Rights Reserved.
35 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 36© 2004 Accenture All Rights Reserved.
36 | 21 Oct, 2004 | oSAP Program
Stock material process flow
Component assignment
Material reservation
Order release
Printing
Goods issue
Automatic availability
check
Availabilitycheck
Copyright © 2010 Accenture All Rights Reserved. 37© 2004 Accenture All Rights Reserved.
37 | 21 Oct, 2004 | oSAP Program
Non-stock material process flow
Component assignment
Purchase application
Purchase order
Goods receipt
Invoice receipt
Copyright © 2010 Accenture All Rights Reserved. 38© 2004 Accenture All Rights Reserved.
38 | 21 Oct, 2004 | oSAP Program
PM work order release
Effects of order release:
Reservation effective, can be withdrawn
Papers can be printed
Confirmation possible
Goods movement possible
Copyright © 2010 Accenture All Rights Reserved. 39© 2004 Accenture All Rights Reserved.
39 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 40© 2004 Accenture All Rights Reserved.
40 | 21 Oct, 2004 | oSAP Program
Technical order confirmation
Before the work order can be completed:
Time must be confirmed
Goods movement reported
Activity reports completed
0013456998Measurement
readings recorded
Copyright © 2010 Accenture All Rights Reserved. 41© 2004 Accenture All Rights Reserved.
41 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 42© 2004 Accenture All Rights Reserved.
42 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 43© 2004 Accenture All Rights Reserved.
43 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 44© 2004 Accenture All Rights Reserved.
Preventive MaintenancePreventive Maintenance
Copyright © 2010 Accenture All Rights Reserved. 45© 2004 Accenture All Rights Reserved.
Master Data in Preventive Maintenance
Master Data in Preventive Maintenance
Copyright © 2010 Accenture All Rights Reserved. 46© 2004 Accenture All Rights Reserved.
46 | 21 Oct, 2004 | oSAP Program
Master data objects
Plant specific master data objects:
Task list
Maintenance item
Measuring point
Global master data objects:
Maintenance strategy
Maintenance plan
Copyright © 2010 Accenture All Rights Reserved. 47© 2004 Accenture All Rights Reserved.
47 | 21 Oct, 2004 | oSAP Program
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
………………………………………………………………………………………………………………………………………………………………………
Copyright © 2010 Accenture All Rights Reserved. 48© 2004 Accenture All Rights Reserved.
48 | 21 Oct, 2004 | oSAP Program
e.g. strategies, maintenance planner group, work center, equipment
e.g. strategy, Task List planner group, main work center
Task listheader
Task listTask listheaderheader
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 serviceOperationOperationOperation
Maintenancepackage
MaintenanceMaintenance
packagepackage
e.g. operation, time, work center, description, control keySub-operationSub-operationSub-operation
e.g. quantities, BOM items, item category, unit of measure
e.g. Material Numbers quantities, BOM items, unit of measure
e.g. amount, typee.g. Mobile Crane
MaterialMaterialMaterial
Productionresources/tools
ProductionProductionresources/toolsresources/tools
Maintenance task list structure
Copyright © 2010 Accenture All Rights Reserved. 49© 2004 Accenture All Rights Reserved.
49 | 21 Oct, 2004 | oSAP Program
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
Copyright © 2010 Accenture All Rights Reserved. 50© 2004 Accenture All Rights Reserved.
50 | 21 Oct, 2004 | oSAP Program
Preventive maintenance plan
PLAN:
Started on date Some parametres Frequency set 1m 3m 6m 1a 3a"Maintenance strategy" A
ITEM 1WO Header info Tasklist: A
check xcalibrate xtune xreplace valve x
ITEM 2WO Header info Tasklist
lubricate xbalance x
Copyright © 2010 Accenture All Rights Reserved. 51© 2004 Accenture All Rights Reserved.
51 | 21 Oct, 2004 | oSAP Program
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).
Copyright © 2010 Accenture All Rights Reserved. 52© 2004 Accenture All Rights Reserved.
52 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 53© 2004 Accenture All Rights Reserved.
Preventive Maintenance processPreventive Maintenance Process
Copyright © 2010 Accenture All Rights Reserved. 54© 2004 Accenture All Rights Reserved.
54 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 55© 2004 Accenture All Rights Reserved.
55 | 21 Oct, 2004 | oSAP Program
Preventive maintenance planning framework
1M * 1000 H2M * 8000 H3M * 10000 Hetc.
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 *
Copyright © 2010 Accenture All Rights Reserved. 56© 2004 Accenture All Rights Reserved.
Refurbishment processRefurbishment Process
Copyright © 2010 Accenture All Rights Reserved. 57© 2004 Accenture All Rights Reserved.
57 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 58© 2004 Accenture All Rights Reserved.
58 | 21 Oct, 2004 | oSAP Program
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.
Copyright © 2010 Accenture All Rights Reserved. 59© 2004 Accenture All Rights Reserved.
59 | 21 Oct, 2004 | oSAP Program
Questions?
Any Questions?
Thank you