58709771-PM-Module-PPT.ppt

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SAP PLANT MAINTENANCE

SAP R/3 ERP
Accounting Area
Financial accounting (FI)
Controlling (CO)
Asset Accounting (FI AA)
• Human Resources
HR
• Logistics
Production Planning (PP)
Materials Management (MM)
Sales and Distribution (SD)
Quality Management (QM)
Service Management (SM)
Plant Maintenance (PM)

SAP Organizational Structure

PM Overview
Plant Maintenance Introduction
Plant Maintenance Organization
Technical Objects
Break Down Maintenance
Corrective Maintenance
Refurbishment Of Spare Parts
Preventive Maintenance
Work Clearance Management

Plant Maintenance Introduction
 SAP Plant Maintenance automates the process of
performing facility repair and maintenance requests.
 For example,. SAP records a problem that is reported,
labor and materials are planned, costs are recorded,
and then costs are settled
Plant Maintenance operates the overall maintenance
business processes and functions allows a
maintenance organization to:
Identify, document, and correct failures and
degradations of any assets for which they have
responsibility.

Plant Maintenance Process Flow

Plant Maintenance Process Flow
PM Process Flow
Maintenance Order
Notification
Plan
Control
Complete
Schedule
Execute

Plant Maintenance Process Overview

Plant Maintenance Organization
1) Overview of Processes and Available Solutions
Lifecycle of technical Asset
• Investment Planning
• Projects Definition
• Selection of Vendor
• Plant Maintenance
• External Procurement
• shutdown

Characteristics
Classes
Equipment/Functi
onal Locations
Tasks List
Bill of Material
Maintenance
Work Centers
Cost Center
Cost Records
Maintenance
Strategies
Maintenance
Plans
Purchase Order
/Release Order
Master Data
Planning
Order Processing
Purchase
Requisition
Time
Conformation
Capacity Load
Maintenance
Order
Material Issue
Material
Reservation
Maintenance
Notifications
Goods
Receipt/Invoice
Receipt

2) User Interface
Various methods that user connects to SAP
 Power User
 Sporadic User
3) Organizational Levels In Plant Maintenance
 Depending on the Company Structure
Maintenance
planning is either of following type
• Plant-Based (Decentralized)
• Cross-Plant (Centralized)

3) Organizational Levels In Plant Maintenance
Analyze Existing Company Structure
Define Maintenance Plants/Planning Plants
Assign Planning Plant/Work Center
Maintenance planner groups are assigned to
planning plants
Maintenance work centers are assigned to
maintenance plant

Plant Based Organization Structure
Plant Based Organizational Structure

Maintenance Plant & Planning Plant
 The plant, at which the operational systems of a
company are installed, is called the maintenance
plant.
 If the maintenance work is planned at this plant, the
maintenance plant is also the maintenance planning
plant.
 A maintenance planning plant is the organizational
unit in which maintenance requirements are
planned.

Maintenance Planning Plant Structure

Planner Group
 The planners within a maintenance planning plant
are defined by maintenance planner groups.
 The units of capacity in Plant Maintenance are
managed as maintenance work centres in the PM
system.
 The maintenance work centres are usually assigned
to the maintenance planning plant.

Work Centers
 Work center is an organizational unit where work is
carried out.
Ex: Machine, Group of machines or group of persons.
 Work centres belong to the master data in PM and
provide the capacity required to perform a task.
 The basic data contains general data such as work
centre category, description, responsibility, and usage
 Work centers can be linked to:
 Cost Centers, Positions, People

Work Centers
 Functions:
 Costing : To determine the costs of an internal
activity by a product unit
 Scheduling : To determine the dates when
operations should be performed.
 Capacity Planning : The capacity requirements for
the operations in the orders are determined

Technical Objects
Technical Objects
1) Functional Locations
 Functional locations are elements of a technical
structure . We create Functional Structures if we want
to represent systems or operational structures within
our company according to functionality.
 Create functional locations hierarchically, and can
also structure them based on the following criteria:
 Spatial Ex: Buildings.
 Technical Ex: Press or Press Hydraulics
 Process-related Ex: Polymerization,.

Functional Location Creation

Functional Locations
Functional Location Structure

The main Aim of creating Functional Locations is to
Structure a technical System or building into units that
are relevant to Plant maintenance.

Functional Location
Structure Indicator
 The identification for functional locations is
created using the structure indicator. The structure
indicator consists of two input fields:
Edit mask : The edit mask is used to control which
characters may be used for identification (letters,
numbers, or both) and how these characters are
grouped together or split.
Hierarchy levels: The hierarchy levels are used to
define which level ends at which character and how
many hierarchy levels the structure may contain.

A functional location can be identified using a maximum
of 40 characters (= maximum length of the edit mask).

Equipment
2) Equipment
 A piece of equipment could be part of bigger technical
structures or independent
 Piece of equipment is usually represented as single
object(Ex: Pumps, motors, vehicle) for which
maintenance tasks should be performed.

Equipment
 Create an equipment master record for a technical
object if: You need to manage individual data for
the object
 Breakdown, prepared or preventive maintenance task
are required for an object and must be recorded
 Technical data for this object must be collected and
evaluated over long periods of time
 The costs of maintenance tasks for this object are
to be monitored
 Record the usage time of this object at functional
locations

The time-based data can be used to monitor a piece
of equipment dynamically, that is, track changes to the
equipment over a specific period of time.
Purpose of Equipment

Equipment
2) Equipment
 This role contains all the functions that you require to
process equipment.
Equipment Activities in Plant Maintenance (PM)
 Creating a piece of equipment (generally, as
production resource/tool, fleet object)
 Collective entry for equipment
 Changing a piece of equipment
 Data transfer from equipment
 Taking up data transfer

Bills of material are used for different purposes. The usage
depends on the enterprise area
Bill Of Material

Bill Of Material
3) BOM
 The Production Bill of Materials represents a
finished product (parent )made up of different
inventory components (children). During the
production process, you turn the components into the
finished product.
 Components in the production bill of materials are
physical items (for example a screw, a wooden board,
a measured quantity of lubricant or paint), or virtual
objects (one work hour)

Bill Of Material
3) BOM
 The engineering/design bill of material includes all
the elements of the product (from an engineering
viewpoint) and contains the technical data. It is
usually not dependent on the order.
 The costing bill of material reproduces the product
structure and forms the basis for automatic
determination of the material usage costs for a
product. Items that are not relevant for costing are
not included in this bill of material.

Bill Of Material
3)BOM
 The maintenance bill of material has three important
functions:
 It only contains items relevant to Plant Maintenance.
 Structuring of the object : The structure of an object should
be displayed as clearly as possible from a maintenance
viewpoint.
 Spare parts planning in the order: If a bill of material exists
for a technical object, it can be used during the planning
process of a maintenance order for the purpose of spare
parts identification and planning.
 Spare parts planning in the task list: Spare parts can be
planned in the task list based on a bill of material

Bill Of Material
3)BOM
 Instead of a uniform bill of material, these areas use
"their own" bill of material with area-specific data
(for example, production).
 They only evaluate bills of material containing area-
specific data. This results in a targeted bill of material
explosion, whereby only the area-specific data is
made available.

Bill Of Material
3) BOM
 Categories of BOM’s are
 Material BOM
 Equipment BOM
 Functional Location BOM
 A material BOM is a bill of material that is first
created for a material independently of a
technical object. To do this, material creation is
must.
 Create a material BOM for the material

Bill Of Material

Break Down Maintenance
 Using this business process we can report, perform,
and document maintenance tasks that arise suddenly.
 All the resources used, costs, and technical details of
the maintenance task are recorded centrally and can
then be evaluated.
 Usually this process is relevant if a technical asset
exhibits a defect, for example, if a pump is leaking or a
printer is not printing properly.

 Diverse employees can create a maintenance
notification to report the defect.
 The responsible maintenance technician receives
these notifications in his or her work list and makes
the necessary repairs.
 Process Flow
1.Notification & Scheduling
2. Execution
3. Completion

Break Down Maintenance Flow

 Create / process notification
 Generate work list for notifications
 Create / process order
 Confirm time
 Modify technical object structure
 Process Execution
 complete order

Refurbishment Of Spare Parts
Refurbishment of spare parts:
 In a company ,Defective or warn-out spare parts in
storage should be refurbished.
 Refurbishment Process
 Pre Requisites for Refurbishment in Material Master
 Separate Evaluation
 Refurbishment Order
 Check the effects of refurbishments on stock value

Refurbishment Process

 During the refurbishment process, equipment is
maintained by a team of maintenance planners,
maintenance technicians, and store persons.
 After a maintenance technician has determined and
replaced the defective equipment, the maintenance
planner posts the defective item to stock
 After planning has been posted, the maintenance
planner creates and releases a refurbishment order
for the given items.

 Calculated the time and material resources are neede
for the refurbishment.
 The order is conformed and Completed.
 The stock value changes dynamically according to the
condition of the items, with the price of a refurbished
item covering all internal and external material and
labour costs spent on refurbishing.

Preventive Maintenance
 Preventive maintenance work is performed to ensure
optimal operation of equipment & avoid costly
unplanned equipment failure or shutdown.
 To keep down times and maintenance costs
minimum, the technical systems are inspected and
maintained regularly
 Preventive Maintenance Can be followed by 3 Factors
 Time Based
 Performance Based
 Condition based

 Time Based
 In time-based preventive maintenance, the
maintenance tasks are planned and performed
depending on the time-dependent intervals
determined. (Ex ,Every 6 months)
 Performance-Based (Performance)
 This preventive maintenance, tasks are triggered
after a specific performance level has been reached
(Ex, Every 10,000 kms)

 Condition Based
 If the service life is exhausted or if the asset is no
longer in good enough condition to perform its
service to the required quality
 Then the service life must be restored through
maintenance or repair work. These maintenance
tasks are generated and performed based on a
certain asset condition.

Task Lists
 In the company, all inspection and maintenance tasks
that must be performed at regular intervals are
defined in maintenance task lists.
 Task list header data
Maintenance Planning
 Single Cycle Plan (Same activity at regular
intervals)
 Strategy (Maintenance work performed in
different cycles)
Maintenance strategy

 Process in Detail
 Create / process notification
 Generate work list for notifications
 Create / process order
 Plan and schedule order
 Perform work clearance management
 Confirm time
 Perform evaluations in plant maintenance information
system (PMIS)

Corrective Maintenance
 Maintenance actions carried out to restore a defective
item to a specified condition
5 Phases of corrective Maintenance
 Entering Requirement(Notification)
 Planning Orders with Operations and Materials (Planning)
 Monitoring the cost (Control)
 Performing the tasks(Execution)
 Completing the Order and Notifications.(Completion)

ACTIVITIES are work performed for Notifications.Importent for inspection,
they prove that certain tasks have been performed.
TASKS: Describes the Activities that still have to be performed.(Also used for
planning purpose)

5 Phases of corrective Maintenance
 Entering Requirement(Notification)
 Planning Orders with Operations and Materials
(Planning)
 Monitoring the cost (Control)
 Performing the tasks(Execution)
 Completing the Order and
Notifications.(Completion)

 Notification: is the technical object contains the
description about the malfunction or requirement
 Malfunctions and other requirements are recorded in
notification, notifications can be accessed and
processed via a list
 Planning : In this phase orders are created and
planned on the basis of the reported requirements.
Planning compasses the Work to be performed , and
the material required.

 Control: In this phase order runs through the different
phases such as material availability check, capacity
planning.
 Execution: Order is executed in this phase, Required
material for the order is withdrawn.
 Completion: Technical Conformation and Technical
completion.

Work Clearance Management
 This business process to enforce all safety measures
that must be enforced before inspections, repairs, or
preventive maintenance work are performed.
 Maintenance Workers operate in a dangerous
Environment(Ex: High Voltage, Radio Activity).
 The WCM component helps company to control and
monitor safety measures.
 Helps to ensure and secure working conditions for
plant maintenance employees.

Work Clearance Management is integrated into the Plant
Maintenance (PM) component

WCM Process Flow (1)
Order
Work Clearance
Application
Work Clearance
Document
Work Clearance
Document
Create Order
Plan Order/ Request Tag
Out
Specify Object containing
Tag out/Lockout
Approve and Perform
Tag out/Lockout

 Lockout-Tag out (LOTO) or lock and tag is a safety
procedure which is used to ensure that dangerous
machines are properly shut off and not started up
again prior to the completion of maintenance or
servicing work
 Work Clearance Document: This document contains a
detailed description of lockout / tag out .

WCM Process Flow (2)
Release Order
Work Clearance
Application
Work Clearance
Document
Order
Completion
Release Order
Determined
Completing Tagging
Perform Un-tagging
Technically Completing
Order

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