Pm key user presentation- Harith senarath/Janaka Pathmendra

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  • 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

    1. 1. Plant Maintenance Key User Presentation
    2. 2.  SAP - An E.R.P. Package Contents of PM Module Benefits of PM ImplementationERP OverviewERP Overview
    3. 3.  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
    4. 4. E.R.P. : ENTERPRISE RESOURCE PLANNINGFor managing 4M’s of enterprise EFFECTIVELY.EFFECTIVELY.MATERIALMATERIALMACHINEMACHINEMENMENMONEYMONEYWhat is an ERP?What is an ERP?
    5. 5. 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?
    6. 6. Examples of Vendors Providing ERP Packages SAP BAAN JD-Edwards Marshall People-softERP VendorsERP Vendors
    7. 7. Systems, Applications, Products inSystems, Applications, Products inData ProcessingData ProcessingWalldroff, Germany.SAP Stands for?SAP Stands for?
    8. 8. R/3R/3Client / ServerClient / ServerCOCOAMAMPSPSWFWFISISMMMMHRHRSDSDPMPMPPPPQMQMFIFIIntegration Of PMIntegration Of PM
    9. 9.  Overview Plant Maintenance Features of SAP PM Master Data Preparation Plant Maintenance Business Process Report Requirement Critical Success FactorsOutlineOutline
    10. 10. Overview OfPlantMaintenance
    11. 11. 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
    12. 12. 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
    13. 13.  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
    14. 14. Malfunction,RequestActivityMalfunction,RequestActivityMaintenance notificationwhatwhenwheretechnical infobreakdownOrder creationPlanning of taskwhowhen, how longwhich stepsaccount assignmentresourcesExecutionwithdrawalutilitiesprocurementwork stepsTechnical informationmalfunctioncausesobjects affectedactivityMaintenance historyCompletionTaskrequested1111OrderConfirmationClosing22223333 44445555666677778888Operation Maintenance planning Maintenance workshopFundamental Maintenance Processing StepsFundamental Maintenance Processing Steps
    15. 15. Master DataPreparation
    16. 16.  MASTER DATA MAINTENANCE PLANNING NOTIFICATION PROCESSING PM ORDER PROCESSING ( RUSH / UNPLANNED )ORDER SETTLEMENT PM PROCUREMENT & SPARES MONITORING HISTORY & ANALYSESContentsContents
    17. 17. 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
    18. 18. 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
    19. 19.  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..
    20. 20. 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
    21. 21. Multilingual textsInternal noteEquipment usageClassificationDocumentsPartner/AddressesMeasuring pointsPermitsEquipment master recordPM dataLocation dataProduction resources/tools dataSerial number dataGeneral DataEquipment MasterEquipment Master
    22. 22. Advantages of BOMMATERIALS PLANNINGMATERIAL/SPARES PLANNINGLOCATING MALFUNCTIONS
    23. 23. 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.
    24. 24. PLANT MAINT. HISTORYPM Order•Costs•Materials•OperationsEquipment Plant Area(Functionallocation)NotificationMAINTENANCE HISTORYNotification historyOrder historyUsage list (Instll.Period)Master Records•Description of Notif.•Time data,B/D Hrs.•Machine/ Object data•Fault location,Damage•Causes, Action taken•Text,Object
    25. 25. PM BusinessProcess
    26. 26. Preventive Maintenance (Time /Performance Based)Breakdown MaintenanceMaintenance Request / ActivityRefurbishmentCalibration of process instrumentsCapital InvestmentsKey Business ScenarioKey Business Scenario
    27. 27. ScheduledMaintenanceUnscheduledMaintenanceMaintenancePlanSchedulePlanCreate PMOrdersAdjust planneddates if requ’dMaintenanceNotificationManually createordersShort termplanning in orderRelease orderExecutemaintenanceMaint operationcompletion confirmationTechnically completeorderRecord technicaldata in notificationComplete notificationSettlementFunctional Flow SummaryFunctional Flow Summary
    28. 28. 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
    29. 29. PurchaserequisitionCompletionconfirmationMaintenance orderMaintenance orderOp. 10: Internal processingOp. 20: External processingService confirmationGoods receiptInvoice receiptPurchase orderActivity costsActivity costsMaterial ConsumptionExternal Processing FlowExternal Processing Flow
    30. 30. Creation ofservicespecificationsDeterminationof requirementsServiceacceptanceInvoiceverificationServiceentryPOmonitoringOrderingprocessVendorselectionQuotationentryBid invitation- User department- PM Plant maintenance- PS Project systemPO Invoice?=RFQProcurement StepsProcurement Steps
    31. 31. Maintenance orderMaintenance orderInternal Processingoperation 10: ME 3 hoursoperation 20: EL 1 hourExternal processingoperation 30: EXT 1 hourMaterial2 pcs. Material ABCCostsInternal Processing: Rs 500.00External Processing: Rs150.00Material: Rs300.00Total: Rs950.00CostsInternal Processing: Rs 500.00External Processing: Rs150.00Material: Rs300.00Total: Rs950.00Cost ProcessingCost Processing
    32. 32.  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
    33. 33. 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
    34. 34. PM Reports
    35. 35.  List of Breakdown Notifications( Daily &Monthly) Equipment Breakdown History MTTR / MTBR / MTBF Damage Analysis Manufacturer wise Breakdown AnalysisBreak Down ReportBreak Down Report
    36. 36.  Preventive maintenance schedule Preventive maintenance Performance summary Preventive maintenance feed back summary(checklist) Graphical Scheduling Overview Material where used List Cost AnalysisPreventive Maintenance ReportPreventive Maintenance Report
    37. 37.  Planned (Preventive )Maintenance Cost Un-Planned (Breakdown) MaintenanceMaintenance Cost ReportMaintenance Cost Report
    38. 38.  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
    39. 39. Cost at Work Center levelCost of Internal Activity, External Services& SparesActual Cost Vs Planned Budget at work center levelRepairs & Maintenance BudgetRepairs & Maintenance Budget
    40. 40.  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
    41. 41. THANK YOU

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