SAP PM CAPABILITES

1. June 21, 2023
SAP PM CAPABILITITES
Road Map Towards Risk
Based Maintenance

2. 2
Objective
• To discuss effective utilization of SAP PM to adopt Risk Based
Best Maintenance Practices.
• To make SAP PM processes more user friendly.

3. Background Problems
• SAP PM is currently not effectively being utilized as CMMS at our plants.
• SAP PM at FFC is required to be restructured as per standards and best
industry practices.
 Asset Register is required to be structured in line with ISO 14224.
 Review of SAP catalogues required for e.g. damage and cause code, Task
lists in light of ISO 14224 standard.
 The Notification and work order type are not unified with industry practices
which makes it challenging to monitor Maintenance performance.
• Missing Assets Information in Asset Register
• Missing mandatory field in notification/workorder

4. • Maintenance KPI to be monitored on dashboards.
• Improper Notification types are selected during initiation
• Preferred notifications priority is routine High.
• Incorrect Functional Locations /Equipment in Notifications.
• Notification workflows not followed.
• Notification not raised and job being done on Workorder only
• Maintenance history not maintained in SAP
• PMP overdue date can be tempered in the existing system
Background Problems (Continued)

5. • Issuance of material in improper work orders.
• BOMs are missing / not updated
• Spare interchangeability is not available
• Missing Assets in Asset Register.
Background Problems (Continued)

6. SAP PM Capabilities Utilization Road Map
Phase-I Target Date
Re-organizing Plant Maintenance Work Types & Order Priorities
Aug 2023
Notifications/order workflows Simplification
Notification / Workorder Essential - SAP Training - I
SAP Data Stewardship
Sep 2023 ~
Maintenance KPIs Monitoring / Dashboards Configuration
Phase-II Target Date
Asset Criticality Analysis Mar 2024
SAP PM Catalogues Populating as per ISO 14224
Apr 2024
Processing Failure Notification/Mandatory Fields – SAP Training - II
Phase-III Target Date
Asset Register re-structuring as per ISO 14224
Dec 2024
Linking BoM with Assets and defining ICs
SAP PM Notification/Order complete with Task list / MPs
Integration of All Assets (RBI) with SAP
Eclass standard Taxonomy for Plant spare parts

7. Phase-I

8. Existing Notification and workorder types required to be in line with best
industry practices/Benchmarks* to:
a) Improve end user experience in selecting notification/order type
b) Monitor maintenance performance / benchmarking KPIs.
Unifying Notification / Workorder Types with Industry
*Benchmarks:
SMRP- Society for Maintenance & Reliability
Professionals
PMO Model from EPRI
Saudi Aramco Saudi Electric Company
Saudi power Plants

9. Unifying Notification / Workorder Types with Industry
TYPE DESCRIPTION SUB-TYPES/REMARKS
PM PREVENTIVE ORDER SUB-TYPES:
 PMN (Time based)
 LOS (Performance Based)
 Calibration
 Warehouse Spares PM
PDM PREDICTIVE ORDER T&I Thickness Monitoring, Electrical Testing etc.
CM CORRECTIVE MAINTENANCE ORDER SUB-TYPES:
 Run-to-failure (RTF)
 Identified as Malfunction
 Identified from PM/PdM
PAM PROACTIVE MAINTENANCE ORDER SUB-TYPES:
 Improvement
 Modification (OPEX or CAPEX)

10. Unifying Notification / Workorder Types with Industry
TYPE DESCRIPTION SUB-TYPES/REMARKS
PMS Shut Down / Turn Around Orders SUB-TYPES:
 Turn Around Jobs (Repetitive)
 Shutdown Jobs (Repetitive)
 Shutdown Jobs (Non Repetitive)
 Turn Around Jobs (Non Repetitive)
SS SUPPORT SERVICES ORDER SUB-TYPES:
 Workshop Services : For equipment sent directly to workshops, order can be
triggered from PM/CM/PAM
 Vehicle Request : Pool Management
 Quality Notification: Lab related services
OTR Others  Housekeeping related
 Issuance of Consumables
 Buildings /Offices /Facilitates PM /CM
 Weather Management System

11. Work Center Customization
Existing Work Center: 410 Entries

12. • SAP inbox related workflows for notifications are recommended to be
discontinued.
• For Emergency Notifications, the workorder shall be created first by
maintenance (on verbal approval by in-charge) and then related
notification will be generated by concerned Unit.
Simplification of Notification Workflow

13. 13
Proactive to Reactive Ratio
Pending & Overdue Notifications
1
2
Selected KPIs for Dashboard
Pending & Overdue Workorders
3

14. 14
Mean Time Between Failure (MTBF)
Maintenance Cost
1
2
Monitoring Only (Non-KPI)

15. Phase-II

16. • A – Safety Critical
The most important consequence of failure is loss of containment of HAZMAT
with the possibility of causing a Major Accident Hazard (MAH). The elements that
safeguard this integrity are called Safety Critical Equipment.
• B- Business Critical
The next important consequence of failure is loss of operational functionality.
Such consequences are economic (production and/or maint. cost) in broad sense
• C - Non Critical
‘C’- priority asset is allowed to fail because it has virtually no direct impact on
production/safety.
Asset Criticality Analysis

17. SAP Catalogues Populating as per ISO 14224

18. THANK YOU
THANK YOU
THANK YOU

19. Unifying Notification / Workorder Types with Industry
Notification Types Workorder Types Maint Activity / Sub Type

20. Failure Data Requirements