1 SAP SAP PLANT PLANT MAINTENANCE MAINTENANCE
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SAPSAPPLANT PLANT
MAINTENANCEMAINTENANCE
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PMPMPlant MaintenancePlant Maintenance
FIFIFinancialFinancial
AccountingAccountingCOCO
ControllingControllingAMAM
Fixed AssetsFixed AssetsMgmt.Mgmt.
PSPSProjectProjectSystemSystem
WFWFWorkflowWorkflow
MMMMMaterialsMaterials
Mgmt.Mgmt.PPPPProductionProductionPlanningPlanning
QMQMQualityQuality
ManagementManagementHRHR
HumanHumanResourcesResources
SAP Plant MaintenanceSAP Plant Maintenance
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SAP PM - Integration SAP PM - Integration Materials Management (MM) Cost Accounting (CO) Financial Accounting (FI) Asset Accounting (AM) Human Resources (HR) Project System (PS) Production Planning (PP)
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Create Work Orders
Notifications
PlannedWork Orders
Schedule WO’s
Parts/Supplies
Labor
Preventative/PredictiveMaint. WO’s
M a s t e r D a t a
Close and Settle WO
Reporting
Special Tools
Pre-defined work steps
Emergencies
External Services Material
Requisitions
ShopPapers
FINANCIALS
M A T E R I A L S M A N A G E M E N T
PM Integrated EnvironmentPM Integrated Environment
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SAP PM - Workflow
Create Work Orders
Notifications
PlannedWork Orders
Schedule Work Orders
Parts/Supplies
Labor
Preventive Maint. Work Order
Master Data
Close and Settle WO
Reporting
Special Tools
Pre-defined work steps
Emergencies
External Services Material
Requisitions
ShopPapers
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Overall Process Flow:
Preventive Maintenance Schedule
Create Work Order Plan WorkNotification
Parts Collected Perform Work Close Work
Order
Structure(Technical Objects)
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JCC Technical Structure Maintain Functional LocationMaintain EquipmentMaintain ClassificationMaintain AssemblyMaintain Equipment BOMMaintain Task List (General)Maintain Work Center
SAP PM - Master Data
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KEY TERMINOLOGY
Functional Location
The Functional Location is a hierarchy (like a tree structure or organizational chart structure) which identifies the area in a plant site where a piece of equipment is located, where it is installed, and where maintenance is to be tracked. It can be based on floor plan location or on process and instrumentation diagram structure.
SAP
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Functional Location and its hierarchy
Plant Area Building Floor
Location Sub locationRoom
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KEY TERMINOLOGY
Equipment- Individual, physical object which is to be maintained
independently. Costs, where it has been used, and repair history are recorded
SAP
examples: production equipmenttransport equipmentbuildingsmaintenance equipmentutility equipment
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Equipment Master Record
The Equipment Master Record contains the fixed data for equipment, the physical location of the piece of equipment, accounting data, location where the maintenance is to be tracked and location of spare parts.
KEY TERMINOLOGYSAP
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KEY TERMINOLOGY
Spare Part
A Spare Part is a replacement part (pump impeller), collection of parts (pump housing) or complete replacement unit (pump, baseplate, motor). It is a storeroom item which can have a safety stock, or can be ordered only when required.
SAPSAP
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KEY TERMINOLOGY
Bill of Materials (BOM)
A bill of materials is a list of spare parts for a piece of equipment.
SAP
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Maintenance Structuring
The PlantFunctional Locations
Unique Equipment #
Bill of Material
Parts Assignment
Via
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MATERIAL
BILL OFMATERIAL
EQUIPMENT
PROCESS
HIERARCHICAL VIEW OF PLANT EQUIPMENT
SPARE PARTS
PARTS LISTS
PUMPS, MOTORSINSTRUMENTS, ETC....
PROCESS STEP, OR GROUPS OFUNIT OPERATIONS
FUNCTIONALLOCATIONS
LOCATION OR UNIT OPERATIONS
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Task Lists Type
• General Task List- Ideal for plants with multiple pieces of equipment that use routine/common applications.
•Equipment Task List- Most suitable for smaller plants and/or operations for a specific piece of equipment.
•Functional Location Task List - Most suitable for tasks that need to be done in an area versus a specific piece of equipment.
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Work Centers
Definition:A producer of work: a production workcenter is a production train, a maintenance workcenter is a mechanic or production worker doing maintenance tasks.
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KEY TERMINOLOGY
Notification A notification is the request for maintenance to beperformed on a piece of equipment within a functionallocation. It is used to track damage history and activitiesdone on a piece of equipment. A notification can beconverted to a work order where actual work and costcan be tracked.
SAP
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Notifications Purpose
Request for work to be done Capture history for the equipment and the
location Contents
Requester Short Narrative of Problem When the work is required Location/Equipment Cause/Damage Codes Activities done
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KEY TERMINOLOGY
Work Order The work order is used to collect cost information
accumulated from labor, material and services used. Time and resource planing and parts ordering is done through the work order. A work order can be created from a notification or may be created directly.
SAP
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Work Order
Purpose To assign people Order needed parts Link required tasks to the job Collect and track all costs to the job
Contents Carries over info from the notification Printed workorder papers
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Preventive Maintenance in SAP
Task ListMaintenance
ItemMaintenance
PlanMaintenance
Schedule
Maintenance Orders
• Maintenance Strategy (Time
or Performance)
• Maintenance Packages (how
often)
•Operations•Personnel•Materials
•Task List
•Object List(Eq or FLOC)
MaintenanceItem
MaintenanceSchedule
(start date)
MaintenanceCalls (createsworkorders)
Schedule Forecast
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KEY TERMINOLOGY PMO - “Preventive Maintenance Orders”
• Task Lists A library of operations. It provides information on the assigned
work center and the resources required.
• Maintenance Strategies Represent the general scheduling rules for the maintenance
tasks you want to perform. Whether the task is scheduled on time or performance.
• Maintenance Packages Defines the exact number of days, weeks, or months that
activities will be carried out.
SAP
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KEY TERMINOLOGY PMO - “Preventive Maintenance.”
•Maintenance Item Describe which technical objects requiring maintenance, as well as, the maintenance activities and operations to be performed.
•Maintenance Plan Consist of Maintenance Items and a Maintenance Schedule, and is used to determine the due dates for the maintenance operations to be performed on the allocated objects.
•Scheduling The system calculates the start and finish dates of orders or of operations within an order.
SAP
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Malfunction, errorRequestActivity
PM Notificationwhatwhenwheretechnical informationbreakdown
Creating the orderPlanning the task
whowhen, for how longwhat stepsaccount assignment resources
Executionmaterial issueprocuring PRTswork steps
Technical informationbreakdowncausesobjects affectedactivities
PM History
Completion
Requesting amaintenance
task11
Order
Completionconfirmation
Completion
2233 44
55
6677
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Plant PM Planning PM Workshop
SAP PM - Configured System
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No Business Process SAP Module BPP ID1 Display JCC Technical
Structure (Explain the machine decomposition)
PM – Master data
2 Maintain Equipment PM – Master data PM-B0013 Maintain Functional Location PM – Master data PM-B0024 Maintain Classification PM – Master data PM-B0034 Maintain Assembly PM – Master data PM-B0045 Maintain Equipment BOM PM – Master data PM-B0056 Maintain Task List (General) PM – Master data PM-B0067 Maintain Work Center PM – Master data PM-B007
PM Scenarios 1: Master Data Structure
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No Business Process SAP Module BPP ID1 Create maintenance
notification.PM – Notification PM-B008
2 Review notification list PM – Notification PM-B0083 Convert maintenance
notification to work order.PM – Work Order PM-B009
4 Trigger stock reservation for spare parts.
MM – Inventory Management
5 Create PR and release via release strategies
MM – Purchasing
6 Convert PR to purchase order (PO) and release purchase order.
MM – Purchasing
7 Perform goods receipt (GR) for external material only.
MM – Inventory Management
PM Scenarios 2: Maintenance Notification to Costs Settlement
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No Business Process SAP Module BPP ID8 Goods issue of spare parts to
work order.MM – Inventory Management
9 Perform goods return of surplus spare parts.
MM – Inventory Management
10 Enter Actual Work Hour into CATS
PM - CATS PM-B014
11 Transfer actual hours to Work Order.
PM – Confirmation PM-B014
12 Record technical findings. PM – Notification PM-B00913 Close work order technically. PM – Work Order PM-B00914 Perform invoice verification. MM – Invoice Verification15 Settle costs to cost center. CO – Settlement16 Close work order financially. PM – Work Order PM-B009
PM Scenarios 2: Maintenance Notification to Costs Settlement (Cont’d)
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No Business Process SAP Module BPP ID1 Review the Preventive
Maintenance program for FVM machine
Manual -
2 Maintain the maintenance strategies
PM – Preventive Maintenance PM-B010
3 Review the maintenance task lists
PM – Preventive Maintenance PM-B006
4 Maintain maintenance items PM – Preventive Maintenance PM-B0135 Maintain maintenance plan PM – Preventive Maintenance PM-B0126 Schedule maintenance plan PM – Preventive Maintenance PM-B012
PM Scenarios 3: Initial PM Program to Automatic Generation of Maintenance Order
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No Business Process SAP Module BPP ID7 Execute maintenance plan PM – Preventive Maintenance PM-B0128 Review the generated
maintenance orderPM – Work Order Management
PM-B009
PM Scenarios 3: Initial PM Program to Automatic Generation of Maintenance Order (Cont’d)
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No Business Process SAP Module BPP ID1 Maintenance Object class
AnalysisPM – PMIS PM-B016
2 Manufacturer Analysis PM – PMIS PM-B0164 Location Analysis PM – PMIS PM-B0165 Planner group Analysis PM – PMIS PM-B0166 Damage Analysis PM – PMIS PM-B0167 Object statistics Analysis PM – PMIS PM-B0168 Breakdown Analysis PM – PMIS PM-B0169 Cost Analysis PM – PMIS PM-B016
PM Scenarios 4: Plant Maintenance Information System
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SAP PM - BenefitsSAP PM - Benefits
Records History to Location and Equipment Captures all Costs for a Work Order Direct Link to Store room Direct Link to Purchasing Ability to Check for Equipment Spares Ability to View Work Load Capacities Allows for Maintenance Reporting Allows for Comparison of Planned and Actual Costs
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