This flow summarizes the basic process that happens within plant maintenance. There is a section within scheduled and unscheduled maintenance that is exactly the same. In certain instances in the scheduled maintenance process, it could happen that technical data needs to be captured. In this case an activity report notification can be raised.
The PM processing cycle consists of five steps: Step 1 is the notification of a certain malfunction or some other kind of requirement (f.ex. request of reconstruction task) Step 2 creates and plans an order based on the notification. Creating operations, making reservations for spare parts or planning of operation times are typical planning tasks. Step 3 is the order control: availabilities are checked, capacities are made available and order papers are printed. Step 4 is the processing step and includes withdrawal of spare parts from the warehouse and the processing of the order. Step 5 takes place after completion of the work and consists of the confirmation of the actucal work as well as technical confirmation concerning the condition and possible damage of the object. The order will be settled by controlling.
Pm key user presentation- Harith senarath/Janaka Pathmendra
Plant Maintenance Key User Presentation
SAP - An E.R.P. Package Contents of PM Module Benefits of PM ImplementationERP OverviewERP Overview
What is an ‘E.R.P.’ ? Why ‘E.R.P.’ is needed ? Who are Global ‘E.R.P.’ Vendors? What is ‘SAP’ ? What is ‘Client Server’ Technology ?General QuestionsGeneral Questions
E.R.P. : ENTERPRISE RESOURCE PLANNINGFor managing 4M’s of enterprise EFFECTIVELY.EFFECTIVELY.MATERIALMATERIALMACHINEMACHINEMENMENMONEYMONEYWhat is an ERP?What is an ERP?
A Standard Software Package taking care of allthe needs of an enterprise.‘E.R.P.’ integrates business processes acrossthe whole company.‘E.R.P.’ provides & helps the enterprise toadopt latest technology & internationalbusiness practices with minimum ease.Why ERP?Why ERP?
Definition: Maintenance is an action required topreserve or to retain the health of equipment.Importance: Because of the increase in automationand the resulting high fixed costs of operationalsystems, plant maintenance plays a decisive role in thesuccess of any business. Production system need to beavailable 24 hours a day in order to guarantee costeffective distribution of fixed costPlant MaintenancePlant Maintenance
Materials Management Finance / CostingMaterial master AccountingService master Order settlementEquipment Bill of material Cost centerSpare parts planning Activity pricingInventory managementPurchase of materialsServices and contractsQuality Management Asset ManagementInspection of parts Equipment and Asset linkCalibrationProduction Planning Human ResourcePRT Scheduling Man Power CapturingPlant Maintenance IntegrationPlant Maintenance Integration
The operational systems are managed using functional locations,equipment & sub-equipment. Preventive maintenance and inspection plans which are done at a regularinterval are released at a scheduled point of time. Malfunctions and other direct requirements are entered directly asmaintenance notification and forwarded to the respective workshopresponsible for processing. Maintenance tasks are carried out using maintenance orders. Cost captured in the maintenance order is settled against the respectiveproduction cost center. The completed maintenance notifications & orders form the basis forcreating maintenance history.Plant SupportPlant Support
Master Data Functional Location Equipment Catalog Profile (Object, Cause & Damage) Check List (Task List) & Plan Equipment Sub-Equipment Relation Equipment BOM Measuring Points & Counters Process Instruments for CalibrationMaster Data ProcessingMaster Data Processing
Technical Object Management Functional location Equipment master data Permits Partner & Addresses Object link master dataBill Of Material Location specific BOM. Equipment BOM. Assembly / Material BOM.Master RecordsMaster Records
PM Work-Center. PM Task-List -> Service sheet Functional location Equipment General Measurement Point & Counter PM Catalogues. PM Material Master External ServiceMaster Records Contd..Master Records Contd..
A functional location is an element in a technicalstructure, representing an area of a Plant at whichEquipment/s can be installed.Advantages of structuring functional location1. Identifying the locations via codification logic.2. Relationship of Functional Location withOrgnization3. Identifying the hierarchical position in structure4. Generating the reports.Functional LocationFunctional Location
Advantages of BOMMATERIALS PLANNINGMATERIAL/SPARES PLANNINGLOCATING MALFUNCTIONS
Work CentersWork CentersIt defines the group of workmens orsingle person or machine or multiplemachines responsible for carrying outthe activity. This also indicates who issupposed to carry out the maintenance.It can be even machines.
Preventive Maintenance (Time /Performance Based)Breakdown MaintenanceMaintenance Request / ActivityRefurbishmentCalibration of process instrumentsCapital InvestmentsKey Business ScenarioKey Business Scenario
ScheduledMaintenanceUnscheduledMaintenanceMaintenancePlanSchedulePlanCreate PMOrdersAdjust planneddates if requ’dMaintenanceNotificationManually createordersShort termplanning in orderRelease orderExecutemaintenanceMaint operationcompletion confirmationTechnically completeorderRecord technicaldata in notificationComplete notificationSettlementFunctional Flow SummaryFunctional Flow Summary
NotificationNotificationOrderOrderControlControlProcessingProcessingCompletionCompletionHistoryMaterial usage, orders, notifications, PMIS, usage listHistoryMaterial usage, orders, notifications, PMIS, usage list• Technical Object• Description• Date• Malfunction•Tasks to perform• Resources int./ext.• Components• Tools• Availability check• Release order• Print papers• Material withdrawal planned/unplanned• External procurement•Time confirmation•Techn.completion• Order settlement• Techn. confirmation4455223311Steps In PM ProcessingSteps In PM Processing
Plant wise view Maintenance Group wise view Planner Group wise view Equipment wise view Functional Location wise view Financial Period wise view Plan vs Actual costCost AnalysisCost Analysis
TYPES OF PM PLANNING2) Counter based maintenanceA - With maintenance strategyB - With multiple counter plan1) Time based planningMonthMonthP1 x xP1 x xP2 x x x x x x xP2 x x x x x x xkilometerkilometerP1 x xP1 x xP2 x xP2 x x
Goods Receipt Goods Issue Spare consumption through MaintenanceOrder(261 Mov. type) Consumption through direct issue to costcenter(201 Mov. type) Consumption actual vs. planned budget Material where used ListSpare Parts ReportSpare Parts Report
Cost at Work Center levelCost of Internal Activity, External Services& SparesActual Cost Vs Planned Budget at work center levelRepairs & Maintenance BudgetRepairs & Maintenance Budget
Condition of a particular Equipment/Functional Location canbe managed by Condition Based Monitoring by usingMeasuring Points & Counters which is created againstEquipment/Functional Location (Trend Analysis),Characteristic Vs Time The Preventive Maintenance (Internal / External) schedule canbe generated with the help of counters ,In case of ExternalProcessing Purchase Requisitions are generated.Condition Monitoring ReportCondition Monitoring Report