I am a SAP S4 HANA Plant Maintenance Lead consultant of 10 yrs of experience and Providing online training for 9 yrs.
Handling Freelancing projects in SAP S4 HANA PM
2. The need for Information
Vision
An Integrated, Flexible and Standardised Information
Systems architecture to position towards
fundamental competitive advantage
Current Reality
Function based Organisation, Multiple stand alone packages,
Time lag between market realities and decision making
SAP
for Enterprise-wide
Transformation.
3. SAP R/3 – The Integrated Enterprise
SAP
R/3
Client / Server
ABAP/4
FI
Financial
Accounting
CO
Controlling
AM
Fixed Assets
Mgmt.
PS
Project
System
IM
Investment Mgmt
IS-Oil
MM
Materials
Mgmt.
SD
Sales &
Distribution
PP
Production
Planning
PM
Plant Main-
tenance
QM
Quality
Manage-
ment
EC
Enterprise
Controlling
LDM
Lifecycle
Data Mgmt
CIN
5. 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
7. 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
8. Using the Navigation Area
You can expand and
collapse menus in the
navigation area by
choosing the dropdown
arrows to the left of the
menu items, as in the
example below
To open an application in
the navigation area
Double-click its node
9. Transaction Codes
A transaction code can be entered in the Command field.
If you precede the transaction code
with /n then the transaction is the
next screen opened in the current session.
If you precede the transaction code
with /o then a new session is opened
for 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 press
enter
Double-click on the required transaction in the tree structure
Position the cursor on the required transaction in the tree structure and select
Edit Execute (or press F2)
Expand the command field and enter the transaction code
10. 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
11. 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
12. 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.
13. Messages appear either in the status bar or in a pop-up window, depending on
user 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 Information
messages
Required fields are denoted by a check mark
Messages
14. Using Online Help
Field Level Help
Used to describe what a
currently selected field is
designed 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 return
to the screen
15. • 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
16. • Enter message
• If the mail is required to
be attended immediately
check ‘Express mail’
• Enter recepient
• Click ‘Send’
• or use tcode ‘sbwp’ and
follow as detailed below
SAP Mail
20. Organization Structuring – 1/5
A grouping of legal,
organizational, business
and/or administrative
units with a common
purpose. Single database
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
21. Organisation Structuring – 2/5
Represents an independent
accounting unit within a
client. Each company code
has its own balance sheet
and its own profit and loss
statement.
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
22. Organisation Structuring – 3/5
Operational unit within
a company code.
•Material Valuation
•Inventory Management
•Material Master
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
23. Organisation Structuring – 4/5
• Maintenance Objects
• Work Centres
• Same as Plant
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
24. Organisation Structuring – 5/5
Planner Groups
• Task lists
• Maintenance Plans
• Order Creation
• Resource Planning
• Work Scheduling
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
25. 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.
27. 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.
PM Functional Location
29. 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 the
likelihood of Damage to the installed aggregates.
Used normally for the object which are not movable.
30. Understanding the Transaction
PM-03-02-01 Master Data – Functional Location
Functional Location Structure using Tcode IH01
List Display of Functional location using Tcode IH06
32. 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
36. 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
39. 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.
40. Bill of material – for equipment
10
Equipment - 10006767
Centrifugal Pump”
Equipment BOM
Casing type A100-100 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
43. 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.
Plant Maintenance task list – Check list
44. 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.
47. Understanding the Transaction
PM-03-02-05 Task List
Display Equipment Task List using Tcode IA03
Cost Maintenance Task Lists using Tcode IA16
Material Where used list: Task List using Tcode IP62
53. 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
54. 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 days
Call horizon at 90% = 81 days
55. Shift Factor
Maintenance item
Maintenance plan
Scheduling data
Cycle start
Technical completion
30/07/2003
Planned date
Cycle 1 month
Shift factor 100%
Planned date
New planned date
30/07/2003(shifted by
100%)
Tolerances can be used in combination with Shift factors to control the
shifting of future planned dates
56. 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
57. 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
58. Deadline Monitoring
= Planned dates
Orders for the
next 90 days
Order
Deadline monitoring
Date of deadline
monitoring run
Order 901760
Cycle 1 month
59. Maintenance Packages Hierarchy
Same hierarchy levels
H1
H1
H
2
H1
Different hierarchy levels
Strategy
Strategy
All the packages are executed which fall due on the same date
The maintenance package with the higher hierarchy suppresses
the lower one when both packages fall due on the same date
60. Maintenance Strategy
Package definition
3 months
6 months
Maintenance Strategy
Scheduling indicator
Time
Time – using key date
Time using Fact. calendar
Strategy unit
Shift factors
Tolerances
Factory calendar
62. Understanding the Transaction
PM-03-02-06 Maintenance Plan
Display Maintenance Plan using Tcode IP03
Schedule Maintenance Plan using Tcode IP10
Scheduling 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 IP43
Maintain Maintenance Strategies using Tcode IP11
Add Strategy control Plan using Tcode IP42
73. 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 Centers in PM
78. Warranties
Warranties define the scope of the services that a Vendor
should provide for a technical object in the event of damage or
problems for the validity period.
Warranties to pieces of equipment of functional locations.
Warranty in PM is :
Vendor Warrantee (for example, manufacturer or vendor
warranty)
82. Classification
Classification system uses characteristics & values to describe all
types equipment, and to group similar equipment in classes.
Classification helps in finding equipment more easily, using the
characteristics defined in them and values as search criteria.
This also helps in finding equipment with similar or identical
characteristics.
83. Classification
Type Centrifugal / Screw /Reciprocating
Capacity 50 m3/hr / 75 m3/hr / 100 m3/hr
RPM 975 / 1450 / 2900
Head 10 Mt / 20 Mts / 30 Mts
Stages 1 / 2 / 3
Fluid Oil / Water / Acids
Class PUMP
–Type
–Capacity
–RPM
–Head
–Stages
–Fluid
Assignment of a pump to
class pump
Assigned values
Type - Centrifugal
Capacity - 75 m3
RPM - 1450
Head - 10 mt
Stages - 1
Fluid - Water
Find a pump in Class PUMP with capacity = 75
m3
Characteristics and Values
Class
Maintenance Classification
Locating a pump
85. Understanding the Transaction
PM-03-02-10 Classification and Permits
Characteristics using Tcode CT04
Classes using Tcode CL02
Find objects in classes using Tcode CL30N
Maintain Permit using Tcode IPMD
86. Now, let us start
understanding what we
discussed, better with
Hands-on Practice using
the Exercise Sheet PM-
02-10.
Let us Get into Hands-
on right now
89. Object Information
The Object Information contains
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.
90. Maintenance Processing
Maintenance Notifications for
Reporting malfunctions, breakdowns
Requesting for maintenance
Documenting the activities performed
Recording technical findings
Technical history of an object gets updated upon
completion of notification.
94. Technical Info.
•Breakdown
•Causes,Activities
•Object affected
PM Notification
•What
•When
•Where
•Technical
Information
•Breakdown
Plant PM Planning PM Work Center
Completion
PM History
PM Order
Completion
Confirmation
1
3 4 5
Completion
6
8
2
Problem , Error
Malfunction,Request,
Activity
Execution
•Material
Withdrawals
•Utilities
•Work steps
Requesting
a Task
PM Order creation
Execution plang.
•Who
•When, How long
•What work steps
•Account Assign.
•Resources
Task Planning.
7
Damage Related Process Maintenance Flow
95. Maintenance Processing
Notification creation
Order
required ?
Order Creation
Order Execution
Material withdrawal Work
Clearance/permits
Technical Completion
Order Settlement Notification Completion
Yes
No
Update technical history
PR creation
Tendering, PO
creation, GR at
stores and
transportation to
local storage as
per MM, OLM
procedure
PR release as per BDP
Business Completion
97. Maintenance Order Processing
Elements of Maintenance Order
Order header
For example: Order Type, Dates,Plant, Main object,
Priority, Description, Maintenance Activity type
Object list
For example:- Functional Locations, Equipment
Maintenance Notifications, Assemblies.
Operation
For 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)
98. 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
99. Stock Material Process Flow
May
Component
assignment
Material
Reservation
Order
Release
Printing
Goods
issue
May
Automatic
availability
check
Availability
check
101. Order Debits after Settlement
Other Postings
Act. Costs > 0
Order Execution
Act. Costs > 0
• Invoice receipts
• Controlling
Postings,
• Completion
Confirmations
• Material
Withdrawals
Maintenance
Order
Order Settlement
After settlement actual
Cost on the Order is
“ZERO”
102. Order Processing Summary
Controlling
Plant Maintenance
Order
• Order not Modifiable
• Postings can be
made to the Order
• Postings cannot
be
Made to Order
Planning
Release
Execution
Completion
Confirmation
Technical
Completion
Settlement
(Business)
Completion
Time
104. Settlement: - Fixed Amount OR percentage Distribution
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.
COST
CENTRE
COST CENTER
(MAINT)
PM Order settlement
107. Order Hierarchy
If maintenance order consists of several independent steps whose
costs should be separated, order hierarchy can be used.
All sub-orders should be completed before a main order can be
completed.
108. Movement Types in PM
101 – Goods Receipt from Vendor
102 – Reversal of 101
261 – Goods Issue from Warehouse to Maintenance Orders
262 – Reversal of 261
201 – Goods from Warehouse to Cost Center
511 – Reversal of 201.
541 – Goods to Vendor for Refurbishment
303 – Transfer Posting to another plant / storage location
305 – Receive material from another plant
109. Understanding the Transaction
PM-03-03-02 Order Processing
Create PM Create Order Processing Tcode IW31(Normal)
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
112. Refurbishment cycle - OEM
Create N9
Notification
CreatePM60 type of
Maintenance Order
Create PR/PO
Uninstall
Equipment .
install at Vendors FL
Create Batch and
And send to stores with
movement type 202
113. Refurbishment Cycle .. contd
Send Equipment
To vendor
movement type 541
Receive Equipment (GR)
Settle & Close Order
Send equipment
To Function location
Movement type 261
Complete Order
114. Refurbishment cycle - Workshop
Uninstall
Equipment
Change Plant ,
Work Center and planner group.
Retain Cost Center of Asset
To Central Workshop
And send to stores with
movement type 202
Transfer Posing from
Asset to Workshop.
Movement type 303/305
115. Refurbishment Cycle .. contd
Create Refurbishment
Order
Replace defective parts
To Asset
Complete the order.
Settle to Asset
Cost Center
Transfer Posting from
Workshop to Asset
116. Refurbishment Cycle .. contd
Send Equipment
From stores to F.
Movement type 201
Install Equipment
117. Create
Notification
‘N9’
IH01or IW21
Create
Purchase
Requisition
ME51N
Create &
release
Service entry
sheet
ML81N
Change Equipment
data & Install at
original location
IE02
Stores to
Functional
location
MB1A (201)
Vendor to
Company after
repair
MB1B (542)
Send to
vendor
MB1B(541)
Release
Purchase
Requisition
ME54
Maintenance
order for
repair ‘PM60’
IW31
Create a
BATCH
MSC1N
Transferring
to Stores
MB1A (202)
Release
Purchase order
ME28
Transaction code
XXX
Refurbishment cycle for repair at OEM/External
Dismantle
equipment &
install at Repair
Location
IE02
Create Purchase
Order
ME21N
Maintenance
order
Completion
IW32 / MIGO /
IW41 / TECO
Complete
Notification
IW22
323
118. Understanding the Transaction
PM-03-04-01
Create PM Create Order Processing Tcode IW31(Refurbishment)
Goods Back to Stores using Tcode MB1A
Goods Transfer Posting Tcode MB1B
Stock Overview Tcode MMBE
Completion Confirmation using Tcode Tcode IW41
Overall Completion Confirmation using Tcode IW42
120. Calibration Processing Cycle
Create Measuring Point
Classification
Assign to Measuring Point List
Calibration
plan
Assign Measuring
List
to task List
Calibration Order
Enter Readings
121. Calibration Cycle
Create Measuring point of Category ‘C’ for each calibration value.
Assign Measurement position for calibration value.
Assign Measuring Point to Task list.
Create maintenance plan wrt to calibration equipment and task list.
Schedule the maintenance plan and release order
Enter the measurement reading for the equipment
Eg for a Diff pressure flow meter with pressure and temperature
corrections and calibration check for 0,25,50,75 and 100% values, 5
measuring points for each parameter ie. totally 15 measuring point
exists for the meter.
122. Understanding the Transaction
PM-03-06-Calibration cycle
Create measuring point IK01.
Create Measuring reading t entry list IK31.
Create Equipment task list IA01
Create measuring plan IP41
Release Order IW32.
Enter measuring reading IK34
125. Plant Maintenance Reports
Analysis of Maintenance Order Costs as per internal labor , material
, services cost.
Monitoring of Maintenance order compliance / back logs for
Planned / unplanned / emergency order.
Break down analysis as per cause , damage and part failure.
Manufacturer wise analysis of Equipment maintenance.
Material Consumption report for Equipment.
Mean time to repair and mean time between failure reports for
Equipments.
Calibration test reports for Instruments.
Measuring value parameters for equipment
126. Understanding the Transaction
PM-03-07-PMIS
Manufacturer Analysis using Tcode MCI2
Planner Group Analysis MCI4
Object Analysis using Tcode MCI6
Cost Analysis using Tcode MCI8
Mean Time Between Repair using Tcode MCJB/MCJC