1. Brief History of SAP
• 1972 Company started
• 1973 SAP R/1 launched
• 1977 First International Customers
• 1979 SAP R/2 solutions launched
• 1988 Company goes public in Germany
• 1992 SAP R/3, ECC6 launched
• S/4 Hana 1909
2. Brief History of SAP
• 1972 Company started
• 1973 SAP R/1 launched
• 1977 First International Customers
• 1979 SAP R/2 solutions launched
• 1988 Company goes public in Germany
• 1992 SAP R/3 launched
• 1996 CRM and SCM solutions launched
• 2004 Central components launched
• 2005 Central components with Netweaver
3. SAP R/3
• POWERFUL TOOL FOR Enterprise Resource
Planning
• TIGHTLY INTEGRATED SAP R/3 Application
Modules
• HIGHLY FLEXIBLE SAP R/3 Basis and
communication System
4. What is SAP R/3 ???
Systems
Applications
Products
In Data Processing
• R Stands for Real Time
• 3 Stands for - Three tier architecture
(Presentation, Application and Data Base)
• Presentation server is the front end
5. SAP R/3
SAP R/3 is an integrated system designed to
cover wide spectrum of business processes.
R - Real Time
3 - Tier
Database Server Application Server
User Front-end
(GUI)
6. Those SAP R/3 software components that
specialize in the management , storage and
retrieval of data form the Database Layer
The Database Layer
Those SAP R/3 software components that
specialize in processing business
applications form the Application Layer.
The Application Layer
Those SAP R/3 software components that
specialize in interacting with end-users
form the Presentation Layer.
The Presentation Layer
SAP R/3 : 3 Tier Architecture
7. Database servers:
Specialized systems
with fast and large
hard drives.
Application servers:
Specialized systems
multiple CPUs and
vast amounts of RAM.
Presentation servers:
Systems capable of
providing a graphical
interface.
Presentation Layer
components
Application Layer
components
Database Layer
components
reside in: reside in: reside in:
SAP R/3 : 3 Tier Architecture
9. PM in SAP Environment
R/3
Client / Server
ABAP/4
CO
Controlling
AM
Fixed Assets
Mgmt.
PS
Project
System
WF
Workflow
IS
Industry
Solutions
MM
Materials
Mgmt.
HR
Human
Resources
SD
Sales &
Distribution
PP
Production
Planning
QM
Quality
Mgmt.
FI
Financial
Accounting
PM
Plant
Maintenance
Overview
SAP R/3
Integration
ABAP
10. PM - Organization Structure
Organization
Client
Plant
Storage location e.g. spares storage
e.g. production sites
e.g. company
e.g. production area,
production engineer
Maintenance plant
Planning plant
Location
Company area
PM planner groups
PM work centers
e.g. plant with technical system
e.g. area, buildings
e.g. plant for maint. planning
e.g. foreman, work preparation
e.g. mechanics, electricians
General organizational units
Location-related organizational units
Planning-related organization untis
13. Technical Object Master Data
•Functional Location
•Equipment
•Bills of material
•Measuring Points & Counters
•Task List
14. Functional Location
Functional locations are the physical locations
of a technical object where equipment can be
installed and dismantled.
Functional Location
Functional Location
19. Equipment
Equipment is an individual object that is to be
maintained independently. It can be installed
and dismantled at functional locations.
• Equipment Types
•Equipment Code Numbering
•Material Code for Equipment
•Warranty Data
•Activating/De-activating
Equipment
Equipment
20. Contents of an Equipment Master
Record
Equipment master record
General data
Location data
PM data
Sales/distribution data
Partner Data
Serial Number
Equipment usage
Classification
Documents
Equipment
22. Maintenance Bill of Material
Bills of material are used to describe the structure of a technical object and to
alllocate spare parts for maintenance purposes.
BOMs for technical objects can be created individually for a specific technical
object or for a group of technical objects.
Level 0
Level 1 Level 1
Level 2
Equipment
Shaft/
Spare Spare Assembly
Spare
Spare
Motor Gearbox
Assembly
Maintenance BOM
24. Technical Objects
Measuring Point
Measuring Point & Counter
You use this component to enter measurement and counter readings for Technical
Objects. This can be of use in the following situations:
You want to document the condition of a technical object at a particular point in
time.
Documenting the condition of a particular object is of great importance in cases
where detailed records regarding the correct condition have to be kept for legal
reasons. This could involve critical values recorded for environmental protection
purposes, hazardous working areas that are monitored for health and safety
reasons, the condition of equipment in hospitals (intensive care units), as well as
measurements of emissions and pollution for objects of all types.
25. Task List
Integration
Using maintenance task lists, you can reduce the time
required to create maintenance orders and
maintenance items as you can refer back to the
operations and sequences already entered in the
maintenance task list.
Moreover, you can include inspection characteristics
from the Quality Management module in maintenance
task lists.
Task List
26. Maintenance Task Lists
Why?
To standardize work flows
To plan maintenance orders more
effectively
To create maintenance plans more
quickly
Task List
27. Task Lists in Plant Maintenance
What ?
Contents ?
Usage ?
Sequence of individual maintenance activities
Execution at regular intervals
Simplified maintenance planning with repeated use
of operation sequences
Work steps (operation)
Maintenance work centers
Times
Material components
Regular maintenance (servicing and inspection)
Ongoing maintenance (planned repairs)
Task List
29. Elements of a Maintenance Task List
Operations
Sub- operations
Material
Maintenance packages
Maintenance task lists
Group ( IH Pumps )
Inspection
Function checks
Mechanical
repairs
Task List
30. PM Task List Groups
Motors: general overhead
Mechanical repairs
group
Counter
01 Maintenance
tasks when
damage x occurs
02 Maintenance
tasks when
damage y occurs
Pumps: inspection
Pumps: mechanical repairs
31. Maintenance Task List Structure
Strategy,
maintenance
planning
group, work
center,
equipment
Allocation of maintenance packages
Work center, description, time,
control key, external processing
data, maintenance packages
Task list header
Operation
Maintenance
packages
Operation, time, work center,
description, control key
Sub-operation
Quantity, BOM item,
item category, quantity unit
Quantity, category
Material
Maintenance
resources
Task List
32. Internal Processing
Operations
External Processing
Control key: PM02 ....
Contents: vendor
purchasing group
net price
purchasing
organization
info record
Control key: PM01 ....
Contents: work center
reference key
length of work
operation duration
wage data
Task List
33. Maintenance Task Lists - Sub-
Operations
Op. Sub-op. WrkCtr Description
0010 ME Clean engine
0010 0010 EL Disconnect electric's
0010 0020 ME Clean engine
0010 0030 EL Reconnect electric's
0020 ME Clean fuel pump
0030 ME Change fuel filter
0040 ME Change oil
0040 0010 ME Remove oil drainage screw
0040 0020 ME Remove preliminary filter case
0040 0030 ME Change paper filter
0040 0040 ME Clean valve bonnet
0040 0050 ME Clean and replace screw
0040 0060 ME Refill oil
0050 ME Check oil level
Task List Group 4711 Diesel Engine Service
Task List
34. Material Components and Operations
PM Task List
Operation 10
Operation 30
Operation 40
BOM
Sub-item 1
Sub-item 2
Sub-item 3
Item 20
Item 10
Sub-item 1
Sub-item 2
Item 30
Operation 20
Task List
36. Preventive Maintenance
Purpose
Preventive maintenance
should maintain the
high availability of
technical systems, for
example, production
plants, in the long
term.
Preventive Maintenance
• Legal requirements
• Customer requirements
• ( for example, automobile industry )
• Reduction of system malfunctions
• Reduction of system restart costs
• Extension of system life
•
• Increased productivity
• Better capacity load control
• Reduction of repair costs
WHY
??
41. Maintenance Plan Structure
Due date forecast
03.04.04
03.06.04
03.08.04
Maintenance orders
Maintenance plan
Maintenance items
Maintenance
schedule
Maintenance
task list
Maintenance
strategy
Maintenance Planning
42. Maintenance Plan and Maintenance
Strategy
Package 1
every 2 weeks
Package 2
monthly
Package 3
half-yearly
Package 4
every 2 years
Strategy " STRATXY "
Maintenance Plan
STRATXY
item
. . .
. . .
Vorgangsliste
Routine inspection
Pressure check
General overhaul
Operation List
Maintenance Planning
43. Maintenance Item - Contents and
Structure
Maintenance Item
FunctLocation
Equipment
Assembly
Object list
Operations
Task list
Operation List
Strategy
Item data Description
Primary object
Work center
Planning data Order type
Planner group
Type
Task list data
Group
Maintenance plan data
Location / account
assignment data
44. Maintenance Item and Maintenance
Task List
General data:
Task list : A
Group: 200174
Group counter : 1
Operation data:
Operation 10: 1M 4M
Operation 20: 1M 4M
Operation 30: 6M
Operation 40: 1M 4M
Maint. Task List
Maintenance Item
Item data
Planning data
PM task list data
1M 4M 6M
Type: A
Group: 200 174
Group counter: 1
Maintenance plan data
Maintenance Planning
46. Scheduling Functions
Restart
Start in cycle
Schedule
Manual call
Function
Date on which maintenance
was to/is to begin
Last actual date
Last maintenance package
Last actual date
Next planned date
Maintenance package
to be performed
Details Required
Maintenance Planning
50. Maintenance Processing
Break Down Maintenance
Features
Maintenance processing can be divided into the
following three areas:
Maintenance Processing
Description of the
object condition
Maintenance
Notification
Execution of
maintenance
tasks
Maintenance
order
Completion of
maintenance
tasks
Maintenance
History
51. Basic Steps in Maintenance Processing
Malfunction, error
Request
Activity
PM Notification
what
when
where
tech. information
breakdown
Creating the order
Planning the task
who
when, for how long
what steps
account assignment
resources
Execution
material issue
procuring PRT’s
work steps
Tech. information
breakdown
causes
objects affected
activities
PM History
Completion
Requesting a
maintenance
Task
1
Order
Completion
confirmatio
n
Completion
2
3
4
5
6
7
8
Plant PM Planning PM Workshop
Maintenance Processing
52. for requesting a maintenance activity/task
for describing a maintenance activity that has already
been performed - purely technical documentation
for describing the condition of a maintenance object
and the malfunction in particular
Definition of a Maintenance Notification
Malfunction report
Activity report
Maintenance request
Notification
53. Structure of Maintenance Notification
Damage, Cause & Object
date/time/reported by
description
PM object: functional location
equipment
assembly
location data
account assignment data
bre/availaakdownbility data
activity
performed by
Activities
dates
task description
Maintenance
tasks
Text
Notification
items
Notification
Damage, Cause & Object
date/time/reported by
description
PM object: functional location
equipment
assembly
location data
account assignment data
bre/availaakdownbility data
activity
performed by
Activities
dates
task description
Maintenance
tasks
Text
Notification
items
Notification
54. Maintenance Order Functions
External
processing
Costs
Task list
BOM
Materials
Capacity planning
Operations
Work centers
Object list
Objects
Completion confirmation
Invoice receipt
Goods receipt
Purchase orders
Material issue
Shop papers
Order
Project
Asset
Cost center
Planning
Execution
Settlement
Maintenance order
55. Structure of the Maintenance Order
Settlement rule
Costs
E.g. order type, dates, plant,
primary object,
priority, description, location
data,
account assignment
equipments (and assembly),
functional
locations, maintenance
Notification
E.g. work center, control
key,
description, standard time,
activity
type, wage details
E.g. quantity,
unit, storage,
location,
availability,
item category
Object list
Order header
Object list
Operation
Sub-operation
Material
Location/account
assignment
Maintenance
resources
Maintenance order
56. Text
Cost Display in the Maintenance Order
Maintenance Order
Internal Processing
Op. 10: ME 3hrs.
Op. 20: EL 1hrs.
External Processing
Op. 30: External 1hrs.
Stock material
2 pcs. Material ABC
Non-stock-material
2 pcs. Material XYZ
Costs
Internal processing: Rs 300
External processing : Rs 75
Stock material: Rs 200
Non-stock-material: Rs 300
Total: Rs 875
Maintenance order
57. Text
Internal Operation
Planned values
Open item +
Order Costs
Planned costs
Actual costs
Reservation
Purchase Order
Invoices
Standard cost estimate
Actual costs
Purchase Order
Capacity load Job-time confirmation
Goods issue
Actual costs
Open item -
Stock material
Goods receipt/
Invoice receipt
Non-stock material
Maintenance Order
External Operation
Maintenance order
58. Releasing an Order
Reservation effective,
material issue possible
Shop papers can be printed
Completion confirmation possible
Goods movement possible
Maintenance order
59. External Procurement Processing in the
PM Order
PM Order
Cost of non-stock
materials
Purchasing Invoice
Verication
Difference between order value and invoice value
Purchase order
value
Allocation of
non-stock material
Invoice receipt
Goods receipt
Purchase order
Purchase
requisition
Maintenance order
62. Job-Time Completion Confirmation
Entry Completion confirmation
Operation list
Scope Partial confirmation
Final confirmation
Cancellation option
Maintenance order
63. Technical Completion Confirmation
Cause of Damage
Object damage locations Items
Maintenance tasks
Activities
Downtimes Time from/to
Downtime duration
System availability Before malfunction
After malfunction
After maintenance task
Defect classification
Maintenance order
67. Order Settlement - Receiver Category
Cost
Center
Asset
Project
Order
Maintenance order
68. Text Text
Settling a PM Order
PM Order 100341
Reference Funct. location
object: C1-B01
Cost center 511
Actual costs: $1200
Object list
- Equipment 05P1234
- Equipment A4321
- Equipment WZ-12-01
Cost center 511
- PM Order
100341 $1200
- . . .
Settlement
Maintenance order
69. Completion Confirmation
Logistics Plant maintenance Maintenance processing
Compl. confirmation Order operations
With Compl. Conf. No
With operation list
Display
Cancel
Maintenance order
72. Refurbishment
Dismantling of faulty equipments and return to
warehouse for refurbishment
Material with condition-based value linked to the equipment is used to monitor
availability of stock in inventory management
Material
condition-based valuation
Valuation type
C2 (refurbished)
$ 2500
Valuation type
C3 (damaged)
$ 200
Valuation type
C1 (new)
$ 3000
74. Refurbishment
Dismantling of faulty equipments and return to
warehouse for refurbishment
Material with condition-based value linked to the equipment is used to monitor
availability of stock in inventory management
Material
condition-based valuation
Valuation type
C2 (refurbished)
$ 2500
Valuation type
C3 (damaged)
$ 200
Valuation type
C1 (new)
$ 3000
76. Maintenance History
Maintenance Processing
Purpose
When managing technical systems, you not only
want to document and support the planning of
maintenance processing, you also want long-term
verification documents in the form of a maintenance
history.
Implementation Considerations
A long-term maintenance history (PM history) is
important for the following reasons:
Recording maintenance activities
Investing in replacements
• Repetitive planning
79. Information Systems
Purpose
The Plant Maintenance Information System can be used at a variety of levels in
the decision-making process as an instrument for monitoring, controlling and
planning your business operations.
The Plant Maintenance Information System allows you to evaluate breakdown
behavior, or the maintenance tasks of a technical system or machine. It is also
possible to analyze the costs incurred or the party responsible for the
maintenance tasks and the exact activities that have been performed. It is used
in:
• Reporting
•Standard
•Customised
•Business Warehouse
Info. System
81. Plant maintenance Cycle
Structuring of the Technical Assets
Hierarchical Structures
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
82. Plant maintenance Cycle
Equipment master Data Maintenance
Integration with Fixed Assets
Classification
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
83. Plant maintenance Cycle
Concept of Measuring Points
Possible sources of Measurement Data
Frequency of the measurement
Trigger of Maintenance activities based on the measurement data
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
84. Plant maintenance Cycle
Task Lists
Monitoring of Notification / Maintenance orders
Maintenance Execution
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
85. Plant maintenance Cycle
Shutdown Planning
Multiple Maintenance orders
Maintenance Execution
External services procurement
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
86. Plant maintenance Cycle
Attaching Maintenance orders to Projects
Scheduling of all orders thru Projects
Tracking of Shut down using PM / PS
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
88. Plant maintenance Cycle
Completion of maintenance
Closing of Notification
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
89. Plant maintenance Cycle
Settlement of Orders – Cost Centre and other Cost Objects
Equipment
Masters
Condition
Based
Maintenance
Shut Down
Maintenance
Notification
Closure
Maintenance
Order
Closing
Settlement
of Order
Integration
with
Projects
Functional
Location
Preventive
Maintenance
Analytics
90. Integration with other modules
Finance/costing
• Asset accounting
• Cost center accounting
Material Management
• Purchase requisition/Purchase order
• Service master
• Service entry sheet / Invoice
verification
Info. System
91. Integration with other modules
•Project system
• Budget
• Project order
• Shutdown planning
•Quality Management
• Calibration order
• Inspection recording
Info. System
