The document outlines a training program for beginners on the ERP PM module, covering essential topics such as creating and processing maintenance notifications and orders, and the Work Clearance Management (WCM) process. It explains key concepts, differences between terms like plant and maintenance plant, various types of notifications and orders, and steps involved in applying and issuing permits for maintenance work. Additionally, it provides details on statuses, tagging conditions, and procedures necessary for the efficient management of maintenance tasks within an ERP system.

1. ERP PM MODULE
Training For
Beginners
(16th
April – 18th
April, 2012)
SSTPS

2. TOPICS – DAY 1
1. Introduction on ERP
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects
(PTW)
5. Receive PTW & Return PTW
6. Important points on WCM
PMI

3. TOPICS – DAY 1
1. Introduction on ERP
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects (PTW)
5. Receive PTW & Return PTW
6. Important points of WCM
PMI

4. PMI
All documents are worthless until
the day of emergency…… And when
the emergency arise, they are hard
to find.
- Bill Gates
INTRODUCTION

5. PMI
FAQ’s in ERP/ PM…
 What does SAP R/3 stand for?
SAP is Systems, Applications and
Products
R/3 stands for Real Time 3-Tier
architecture
3 Tier : - Client Computer
- Application Server
- Data base server

6. PMI
FAQ’s in ERP/ PM…
 What is ERP?
Enterprise Resource Planning
Cross-functional, integrated application
package to automate & manage business
processes
ERP encompasses best-practices adopted
across the globe
Various options are available, which can be
configured to suit our business
requirements

7. PMI
FAQ’s in ERP/ PM…
 What is the difference between Plant and
Maintenance Plant in ERP?
Plant is one organizational unit of a business
enterprise
Plant is created by Finance Module (FI) &
Material Module (MM)
Maintenance Plant is any area where the
technical objects (machines) are installed
and where maintenance is done.
The Plant created by MM & FI is taken as
Maintenance Plant as it is in PM.

8. PMI
FAQ’s in ERP/ PM…
 What is Planning Plant?
Planning Plant is the organisational unit
responsible to plan all type of maintenance
activities (can be centralised)
 What is Planner Group?
Planner Groups are the groups which plan
the maintenance activities of different
sections on day to day basis

9. PMI
FAQ’s in ERP/ PM…
 What is Functional Location?
 Functional locations are hierarchically ordered structure elements
of ERP that represent a technical system, building, or part thereof.
 It contains a group of equipments which form a system.
 The code for Functional Location is assigned based on the
specified structure indicator
 What is an Structure Indicator?
Alpha-Numeric string used to codify Functional Locations:
XXXX-XXXXX-XXX-XXX-XXX-XXX
Hierarchy levels 1 2 3 4 5 6
e.g. 1034-S1U01-BLR-FF1-CR4-GUN
Ramagundam unit-1 boiler firing floor elevation-1 corner-4 gun

10. PMI
FAQ’s in ERP/ PM…
 How does Equipment differ from Functional
Location?
Equipments are objects that need to be maintained
individually
Equipments are installed on Functional Locations
An Equipment can be moved from one Functional
Location to another if required during maintenance,
but its identification number does not change
A unique identification number is given for an
equipment when it is created in the system.
The OEM provided identification (KKS codes) are
maintained in a field named “Technical Identification
No.”

11. PMI
FAQ’s in ERP/ PM…
 What is Notification?
Notification is a SAP equivalent of defect registration
Operation Engr. will normally create a Notification for a
break-down or general maintenance type of job
In SAP notification is also used to transfer an
information in documented form, which is traceable
A notification carries the defect or job related history of
the equipment

12. PMI
FAQ’s in ERP/ PM…
 What is Maintenance Order?
Maintenance Order is the SAP equivalent of Job
Card
It carries the details of work done, time of start, end
time, material & services consumed
It forms the basis of cost of maintenance
It is mandatory to create MO to draw material from
stores or create Service entry

13. PMI
FAQ’s in ERP/ PM…
 What is WCM?
WCM means Work Clearance Management. It is SAP
equivalent of Work Permits
Three Level of WCM: - WA i.e. Work Approval
- WCA i.e. Work Clearance
Application
- WCD i.e. Work Clearance
Document
One WA is created for one Maint. Order
Each WA has one or more WCA assigned
WCD is assigned to a WCA
There is provision of tagging/ untagging in the system to

14. TOPICS – DAY 1
1. Introduction
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects (PTW)
5. Receive PTW & Return PTW
6. Important points on WCM
PMI

15. TOPICS – DAY 1
1. Introduction
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects (PTW)
5. Receive PTW & Return PTW
6. Important points on WCM
PMI

16. Notification Types
• M1: General nature of jobs lighting defects, connection
removal etc. Goes to Maint directly.
• M2: Jobs requiring any kind of corrective action to
prevent break-downs OR to attend break-downs. E-
priority goes to Maint directly. Others are routed through
MTP
• M3: Jobs which require Condition Monitoring Group to
analyse first. MTP will then raise notification to
concerned maint section.
PMI

17. Notification Types
• M4: Raised by system when measurement
documents are created manually by a user in
case of deviations
• M5: Raised by system when measurement
documents are created by system in case of
deviations
• Others are raised by Safety or FQA deptts.
PMI

18. Flow of Different Notification Types
M1 M2 M3
Priority?
Concerned Maintenance Section
E A/B
MTP
(for scheduling)
CMG
(To assess
Condn)
M4
PMI

19. Notification Statuses
• OSNO: Outstanding Notification
• ORAS: Orders Assigned
• OSTS: Outstanding Tasks
• ATCO: All Tasks Completed
• NOCO: Notification Completed
• DLFL: Deletion Flag Set
USER STATUS
• MTP: MTP to take action
• MNT: Maintenance to take action directly
• SCHD: Scheduled by MTP, now Mtc to take action
PMI

20. PROCESS IN SYSTEM

21. TOPICS – DAY 1
1. Introduction
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects (PTW)
5. Receive PTW & Return PTW
6. Important points on WCM
PMI

22. Order Types
• PM01: General Maintenance
• PM02: Corrective Maintenance (B/Dn)
• PM03: Preventive Maintenance
• PM08: Overhauling Maintenance
• WKSP: Workshop Orders
• ZFQA: FQA Orders
PMI

23. Order Statuses
• CRTD: Created (Outstanding)
• WCM: WCM Enabled (cannot be closed w/o PTW)
• REL: Released (In Process)
• RELR: Release Rejected (Cost Center not defined)
• CNF: Confirmed
• PCNF: Partly Confirmed
• SETC: Settlement Rule Created
• GMPS: Goods Material Posted/ SES Done
• MSPT: Material Shortage
PMI

24. Order Statuses
• MANC: Material Availability not Confirmed
• NMAT: No Material
• WOCO: Work Completed (Permit Return)
• TECO: Technically Completed
• CLSD: Closed
• NCMP: Work Not Completed
PMI

25. PROCESS IN SYSTEM

26. Introduction to WCM
WCM means Work Clearance Management
Maintenance Work on a machine requires its Clearance from
process side before start of work to ensure safety of the working
person as well as other machines nearby. WCM is all about
Managing this SAFETY aspect.
PMI

27. DISCH V/V
SUCN V/V
VENT V/V
DRAIN V/V
ELECTRICAL
MODULE
TYPICAL ISOLATIONS OF A PUMP
PUMP-1A: Eqpt to be isolated
PMI

28. Isol
No.
Technical Object Tagging Condition
1.
2.
3.
4.
5.
Electrical Module
Discharge Valve
Suction Valve
Drain Valve
Vent Valve
OFF
CLOSE
CLOSE
OPEN
OPEN
PMI
Isolations : as defined in ERP
Isolations : as defined in ERP
WCD

29. Introduction to WCM
• PM ORDER
WCM Objects:
• Work Approval (WAP):
Agreement between Operation & Maintenance to take up maint job
• Work Application (WCA):
Application for the PTW- 6 types of applications, e.g. LWC, HWP, PTW etc.
• Work Clearance Document (WCD):
Isolations List with specific isolating object and tagging condition
PMI

30. WCM: Work Clearance Management
Other Terms related to WCM:
• Operational WCD:
Isolation list created for each PM Order – it’s a transactional data
• WCD Template:
A Master Isolation List for each equipment. It can be different for different kind
of maintenance on same equipment
PMI

31. WCM: Work Clearance Management
Other Terms related to WCM:
• Technical Objects:
• Objects which are involved in the isolation of equipment
under maintenance
• These are unique for each WCD and form the basis for
CROSS-PERMITS
• These objects could be Functional Location (F), Equipment
(E) or No Master Record (N)
• N type of object need to be defined ensuring uniqueness
PMI

32. WCM: Work Clearance Management
Other Terms related to WCM:
• Tagging Conditions:
• Conditions which describe the status of the Technical Object
to ensure isolation of the Equipment under maintenance.
• There are two types of Tagging Conditions:
• Electrical – e.g. ETAG01 (Bkr in Test Position)
ETAG09 (Module Off, Fuses removed & locked)
• Mechanical – e.g. MTAG01 (Under Shutdown)
MTAG18 (Valves Damper Closed)
PMI

33. WCM: Work Clearance Management
Other Terms related to WCM:
• Untagging Conditions:
• There is always a corresponding set of Untagging Conditions
to each Tagging Condition, which describes the status of the
Technical Object ready for operation
PMI

34. WCM Statuses
• CRTE: Created (All – WA, WCA, WCD)
• PREP: Prepared (All – WA, WCA, WCD)
• PROC: In Process (WCD)
• CHNG: In Change mode (WCD)
• ITG: Initial Tagging (WCD)
• ETG: Tagged (WCD)
• UNT: Untaggable (WCD)
• EUG: Untagged
• CLSD: Closed (All)
PMI

35. TOPICS – DAY 1
1. Introduction
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects (PTW)
5. Receive PTW & Return PTW
6. Important points on WCM
PMI

36. TOPICS – DAY 1
1. Introduction
2. Create & Process PM Notification
3. Create & Process PM Order
4. Create & Prepare WCM Objects (PTW)
5. Receive PTW & Return PTW
6. Important points on WCM
PMI

37. PROCESS IN SYSTEM
Steps involved in applying a permit (by Maint):
1. WCM-enabling the PM Order
2. Creating Work Approval (WAP)
3. Creating Work Application (WCA)
Selecting the type of Application (WC, LWC, HWP, WPH,
CSP or FOP)
4. If WC is selected, then Creating WCD
5. Preparing WCD, WCA & WAP

38. PROCESS IN SYSTEM
Steps involved in issuing a permit (by Operation):
(For LWC, HWP, WHP, CSP or PFO)
1. Use t_code WCLE. Enter Plant code & select radio button –
Work Approval and execute.
2. In the next screen select radio button beside Red traffic light.
3. Check the box ‘Prepared’
4. Enter the ‘Valid From & To Dates’, preferably from previous day’s
date to next day’s date, & execute
5. From the list select the WAPs which are to be issued
6. Issue Work Approval: Traffic light of WAP changes from Red to
Yellow.
7. For WCA, other than WC Application, each Application is to be
issued individually & traffic light changes from Red to Green.
8. Press Refresh button: Traffic light of WAP changes to Green
9. Print PTW

39. PROCESS IN SYSTEM
Steps involved in issuing a permit (by Operation):
(For WCD)
1. Steps 1 to 6 are same as in previous slide.
2. Press Refresh button:, the traffic light of WCA (& its associated
WCD) changes from Red to Yellow.
3. Go to Switching Screen
4. Sett each isolation to ‘Tag’
5. Print Isolation Slip
6. Set each isolation to ‘Tagged’: Traffic light of WCD changes to
Green
7. Again Refresh: Traffic Lights of WAP & WCA also change to
Green.
8. Print PTW.

40. PROCESS IN SYSTEM
Steps to be taken by Maint after issuing of permit:
1. Open the Order in Change mode (IW32/ IW38)
2. Press the button ‘Release for Execution’
3. Status of Order updates from CRTD/REL to EXEC
4. A new button ‘Work Completed’ appears in place of ‘Release for
Execution’
5. After the work at site is complete, Press the button – ‘Work
Completed’
6. Status of Order changes to WOCO. This means permit is
returned in the system.
7. Return the PTW print-out

41. PROCESS IN SYSTEM
Steps to Close permit (by Operation):
The WAP & WCA gets closed automatically as soon as the Order is
set to WOCO. So in cases of LWC, HWP, WHP, CSP & PFO,
Operation has nothing to update in the system.

42. PROCESS IN SYSTEM
Steps to Close permit (by Operation):
For WCDs following steps are required:
1. Again use t_code WCLE and select the Work Approval button.
2. In the next screen, select the Green radio button
3. Enter the relevant Valid From & To dates & execute
4. WAP & WCA already show CLSD status. A new status UNT
appears on WCD which signifies that WCD is now Untaggable
5. Click on the Switching Screen
6. Select all isolations and press ‘Untag’
7. If there are any cross permits, system will show it either in red,
yellow or green pop-ups
8. If only yellow or green pop-ups appear, go on pressing Enter
button until all isolations are untagged
9. If any red pop-appears, it means that there is still a cross WCD
which is yet to be set as UNT.
10. Untag it later, after all the permits are returned. Then closeWCD.

43. DISCH V/V
SUCN V/V
VENT V/V
DRAIN V/V
ELECTRICAL
MODULE
TYPICAL ISOLATIONS OF A PUMP
PUMP-1A: Eqpt to be isolated
PMI

44. DISCH V/V
SUCN V/V
VENT V/V
DRAIN V/V
ELECTRICAL
MODULE
TYPICAL ISOLATIONS OF A PUMP
PUMP-2B
PMI

45. Isolations of 2 difft EQs at same time
Isol
No.
Technical Object Tagging
Condition
1.
2.
3.
4.
5.
Electrical Module
Discharge Valve
Suction Valve
Drain Valve
Vent Valve
OFF
CLOSE
CLOSE
OPEN
OPEN
PUMP-2B
PUMP-1A
Isol
No.
Technical Object Tagging
Condition
1.
2.
3.
4.
5.
Electrical Module
Discharge Valve
Suction Valve
Drain Valve
Vent Valve
OFF
CLOSE
CLOSE
OPEN
OPEN
Time required for Maint = 1 Hr Time required for Maint = 4 Hr
CROSS
PERMIT
WHERE
NOT REQD
PMI

46. Isolations of 2 difft EQs at same time
Isol
No.
Technical Object Tagging
Condition
1.
2.
3.
4.
5.
1024-S1U01-LTS-00A
1024-S1U01-VLV-DIS
1024-S1U01-VLV-SUC
24-U1-PMP-A DRN VV
24-U1-PMP-A SUC VV
OFF
CLOSE
CLOSE
OPEN
OPEN
PUMP-2B
PUMP-1A
Isol
No.
Technical Object Tagging
Condition
1.
2.
3.
4.
5.
1024-S1U02-LTS-00B
1024-S1U02-VLV-DIS
1024-S1U02-VLV-SUC
24-U2-PMP-B DRN VV
24-U2-PMP-B SUC VV
OFF
CLOSE
CLOSE
OPEN
OPEN
PMI
THIS IS DEFINED AT WCD LEVEL

47. Isolations of same Eqt but required
by 2 difft deptts at same time
Isol
No.
Technical Object Tagging
Condition
1. 1024-S1U01-LTS-00A OFF
Mechanical
Electrical
Isol
No.
Technical Object Tagging
Condition
1.
2.
3.
4.
5.
Electrical Module
Discharge Valve
Suction Valve
Drain Valve
Vent Valve
OFF
CLOSE
CLOSE
OPEN
OPEN
NO CROSS
PERMIT
PMI
PUMP-1A

48. Work Approval
• Work Approval (WAP):
• Is always created from WCM-enabled Order
PMI
WCM Status on order &
Work Approval button
appear simultaneously
Dumbbell is CLOSED
when WAP is created

49. Work Approval
PMI
Assignment-1
Assignment-2
• Work Approval (WAP):
• Proper WAP always has two objects assigned: Order &
Work Application (WCA)

50. Work Approval
• Work Approval (WAP):
• Only one WAP can be assigned to one Order
• One WAP can have more than one WCA assigned
• Series of WAP numbers start from 10….
PMI

51. Work Approval
• WA is created & prepared by Maint deptt, hence it is
responsibility of Maint deptt to ensure correct
creation.
• If Operation deptt finds such incorrect WAs, they
SHOULD NOT issue these. Note down the no. and
inform to Maint deptt.
PMI

52. Work Application
• Work Application (WCA):
• Is always created from WAP
• More than one WCA can be assigned to single WAP
(Enhancement Model)
• But one type of WCA can be assigned only once.
• When Isolation permit (PTW) is to be applied, WCA type
‘WC Application’ is selected.
• WC Application type of WCA always has two
assignments – WAP & WCD
• Other types are HWP, LWC, CSP, WHP & PFO. These have
only one assignment – WAP.
PMI

53. Work Clearance Application
PMI
While creating WCA, only one can be selected at a
time. Go back to WA screen to create another WCA.

54. Work Application
• Types of WAPs & No. Series:
Type No. Series
WC Application 10…..
Hot Work Permit 20…..
Limited Work Permit 30…..
Confined Space Permit 40…..
Working at Height Permit 50…..
Permit for Floor Opening 60…..
PMI

55. Work Clearance Document
• Work Clearance Document (WCD):
• Is always created from ‘WC Application’ (specific type of
WCA)
• Only one WCD can be assigned to one WC Application
• One or more Tagging Conditions are assigned in WCD
• Keep track of different stages of the Tagging Conditions.
PMI

56. Operational WCD vs. WCD Template
• Operational WCDs are those which are created on
day to day basis for isolations/ normalisations.
• These are required to be closed at the end of the
job.
• These come under transactional data.
• Their number series is 30…
• In contrast WCD Templates are standard list of
isolations.
• They form the master data of WCM
• Their no. series is 10…
PMI

57. Using WCD Template
• Go to Enhancement screen & select the
appropriate WCD template from the
dropdown menu.
• All the templates created on the Functional Location of
Order, are listed in the dropdown.
• Check the description and select correct template
• If in doubt, use t_code WCL2 copy paste the template no.
in WC Document No. field and check the isolations
before creating & preparing the WCD. (show in system)
PMI

58. Advantages of Using WCD Template
• Creation & Preparation of WA, WAP & WCD is
simplified to a large extent.
• Chances of error/ undesired cross-permits
are minimized.
• Templates attached to task lists, allow for
automatic creation of WCDs.
• A simplified WCM process, under-
development, is based on WCD templates
alone.
PMI

59. Important Points for WCD Template
• Correct selection is very important
• Some Templates may contain the comprehensive
list of isolations, with certain undesired isolations
for the particular job
• Delete the undesired isolations before PREParing
the WCD.
• Job specific templates may be created
PMI

60. How to Create WCD Template
PMI
• MTP users are authorised to create WCD templates
in bulk.
• Use the excel format ‘WCD Template Upload Format’
given in the Shared folder-PM Help Doc-Master Data
Upload format.

61. Orphan PTWs…
• Means those PTWs which are not linked to any
Maint Order. (In ZPTWREG the Order column is
blank.)
• May be created due to:
• Rescheduling of jobs
• Not saving of order after WCD creation
PMI

62. Orphan PTWs
Missing Orderder
CLSD status missing
UNT status missing
In normal case, i.e. if an order was linked to the WA, status CLSD
comes automatically on Work Completion (WOCO status) of that
order. OPN engr is not required to close these manually.
PMI

63. Orphan PTWs…
• Unnecessary increases the number of
‘Equipments out for more than 15 days’
• Should be deleted immediately when found.
• Not to be issued.
PMI

64. Use of Isolation & Normalisation Slips
• Avoids any communication gap.
• Isolation slip is printed between ‘TAG’ & ‘TAGGED’
Status.
• Adhering to this process will ensure timely closing of
PTWs.
• No. of records in ‘Eqt Out for > 15 days..’ report will
reduce.
• Normalisation slip is printed between ‘UNTAG’ &
‘UNTAGGED’ Status.

65. Isolation Slip: Isolations are NOT printed if not between
Tag & Tagged Status…
PMI

66. Isolation Slip can be printed only between Tag &
Tagged Status…
PMI

67. THANK YOU
Questions Please