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Plant maint
The document provides an overview of SAP Plant Maintenance (PM) modules and processes. It describes the PM organizational structures and master data, including functional locations, equipment, and bills of material. Key PM processes like maintenance notifications, orders, time confirmation and completion are summarized. Breakdown maintenance and its business processes are outlined. The document also discusses maintenance planning, resource availability, and order processing in SAP PM.
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Plant maint
- 1. breaking through barriersto progress Plant Maintenance in SAP A functional perspective an award winning '2004 Future 50 Company' By – Gopinath 18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.0200
- 2. SAP R/3 -Overview Getting Started SAP AG R Overview: R/3 Overview and Integration R//3 SD Salless Distribution MMatteerriiallss MMggmmtt Client / Serrverr ABAP CO Conttrrolllliing AM Asssett MMgmmtt PPSS Project Systtem WFF Workflow IIS Industry SSoolluuttiioonnss MM HR Human Resources PPPP Production PPllaanniinng QM Quality Mgmt FII Financial Accounttiing PM Pllantt Maiinn-- ttennancce System-Wide Concepts TeamSAP Academy R/3 Overview Integration R/3 Applications Support Services 2
- 3. 3 Plant Maintenance- Overview SD Sales Distrib. Logistics Accounting SAP AG R SAP R/3 Modules Human Resources Cross Application Functions R//3 Client / Server ABAP FII Financial Accounting CO Controlling TR Treasury PS Project System WF Workflow IIS Industry Solutions MM Material Manag. HR Human Resources. PP Production Planning QM Quality Manag. PM Plant Maint.
- 4. 4 Plant Maintenance- Overview R/3 What Is Integration? SAP AG R SD MM PP QA PM HR FI CO AM PS WF IS Common organizational structures throughout the system Seamless processing of common data between applications Comprehensive support and reference tools Common reporting features and functionality Object and application linking and overall system communication
- 5. 5 Plant Maintenance- Overview Organization of Plant Maintenance: Business Scenario SAP AG 1999 Plant Maintenance is an integral part of the company and has numerous links to other enterprise areas. Depending on the company structure, maintenance planning is either plant-based (decentralized) or cross-plant (centralized).
- 6. 6 Plant Maintenance- Overview Structure of Plant Maintenance SAP AG 1999 EQM Technical Data Functional locations Equipment Assemblies Bills of material Networks of technical objects PRM Preventive Maintenance Task lists Maintenance plans WOC Maintenance Processing Maintenance notifications Maintenance orders PMIS Plant Maintenance Information System CRP Work Centers and Capacity Maintenance work centers
- 7. 7 Plant Maintenance- Overview Concept of Plant Maintenance SAP AG 1999 Bills of material Task lists Characteristics Classes Equipment / functional locations Cost records Cost center Maintenance work centers Maintenance notification Material reservation Material issues Maintenance order Capacity load Time confirmation Maintenance strategies Purchase requisition Maintenance plans Master data Planning Order processing Goods receipt / invoice receipt Purchase orders / release order
- 8. 8 Plant Maintenance- Overview Organizational Structures in Plant Maintenance General Organizational Units in Logistics Company code Plant Location-Based Organizational Units Maintenance plant Location Plant section Planning-Based Organizational Units SAP AG 1999 For example, site, building, coordinate For example, production area, plant engineer Client Maintenance planning plant Maintenance work centers For example, foreman, work scheduling For example, mechanics Maintenance planner groups
- 9. 9 Plant Maintenance- Overview Cross-Plant Maintenance SAP AG 1999 Plant 1200 Plant 1300 Maintenance requirement Plant 1000 Workshops Workshops Maintenance requirement Planning of maintenance requirements Maintenance requirement Warehouse Material
- 10. 10 Plant Maintenance- Overview Maintenance Work Centers SAP AG 1999 Maintenance work centers For example: Welding Metalworking Mechanics
- 11. 11 Plant Maintenance- Overview Work Center: Contents Basic data SAP AG 1999 General data Capacity data Capacity categories Scheduling Capacity / pool capacity Available capacity profile T i m e Links Activity types Activity types Cost center Work center Person Qualification Staffing assignment Staffing assignment Activity types Staffing assignment
- 12. 12 Plant Maintenance- Overview Work Center: Main Functions SAP AG 1999 WWoorrkk CCeenntteerr Costing data Costing data Default values for task lists and orders Default values for task lists and orders 10 11 Scheduling data and Scheduling data and available capacity available capacity CCoossttiinngg 2,724.00 1,200.00 124.00 2,724.00 1,200.00 124.00 4,048.00 4,048.00 TTaasskk lliisstt // oorrddeerr Lead time scheduling Lead time scheduling Capacity planning Capacity planning
- 13. 13 Plant Maintenance- Overview Functional location = multi-level, hierarchical structure, SAP AG 1999 Spatial Technical Functional organized according to ... Criteria Functional Location
- 14. 14 Plant Maintenance- Overview Criteria for Functional Locations SAP AG 1999 When is a functional location created? Execution of maintenance tasks Recording of maintenance tasks Data collection over long periods of time Cost monitoring by area What effect do the usage conditions have on the likelihood of damage to the installed aggregates?
- 15. 15 Plant Maintenance- Overview Automatic Assignment Upon Creation SAP AG 1999 C1-B Biological cleaning C1 Clarification plant C1-M Mechanical cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station Existing functional locations New functional locations C1-C1-M01-M01-2 2 Ventilator Ventilator C1-M02-2 Ventilator C1-B01-1 Pump 1 C1-B02-2 Filter cell
- 16. 16 Plant Maintenance- Overview Example of Functional Location Structure SAP AG 1999 C1-B Biological cleaning C1 Clarification plant C1-M01-1 Reservoir C1-M01-2 Ventilator C1-M01-3 Sand dredger C1-M02-1 Reservoir C1-M02-2 Ventilator C1-M02-3 Fat dredger C1-B01-1 Pump 1 C1-B01-2 Pump 2 C1-B02-1 Ventilator C1-B02-2 Filter cell C1-M Mechanical cleaning C1-M01 Sand trap C1-B02-1A Valve 1 C1-B02-1B Valve 2 C1-B02-2A Inlet C1-B02-2B Filtrate level C1-B02-2C Outlet C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station C1-B02-2A/1 Valve 1 C1-B02-2A/2 Valve 2 C1-B02-2C/1 Valve 1 C1-B02-2C/2 Valve 2
- 17. 17 Plant Maintenance- Overview Criteria for Equipment Master Record SAP AG 1999 When is a piece of equipment created? Management of individual data Recording of maintenance tasks Object-based recording of costs Evaluation of technical data Recording of usage times
- 18. 18 Plant Maintenance- Overview Equipment Master Record Equipment maasstteerr rreeccoorrdd SAP AG 1999 Equiipmentt usage Documentts // ttechniicall drawiings Mullttiilliinguall ttextts Measuriing poiintts // countters IIntternall notte Location A Location B Cllassiiffiicattiion List X X X X X X X Address // parttner Permiitts 0 4 7 1 0 1 2 3 GGeenneerraall LLooccaattiioonn OOrrggaanniizzaattiioonn SSttrruuccttuurree
- 19. 19 Plant Maintenance- Overview Bills of Material in Company Production bill of material SAP AG 1999 Engineering/design bill of material Costing bill of material Maintenance bill of material
- 20. 20 Plant Maintenance- Overview Breakdown Maintenance: Business Scenario SAP AG 1999 For breakdown maintenance, the data required for the other business processes needs to entered quickly and easily so that the subsequent steps can be executed.
- 21. 21 Plant Maintenance- Overview Business Process: Breakdown Maintenance 1 SAP AG 1999 NNoottiiffiiccaattiioonn PPllaannnniinngg SScchheedduulliinngg EExxeeccuuttiioonn CCoompplleettiioonn • Technical object • Description • Work to be performed • Internal/external resources History • Date • Malfunction Material PMIS, list Material usage, orders, notifications, PMIS, usage list • Material • Tools • Capacity leveling • Availability check • Order release • Printout • Planned/unplanned material withdrawal • External procurement 1 44 55 22 33 22 33 • Time confirmation • Technical completion • Order settlement • Technical confirmation
- 22. 22 Plant Maintenance- Overview Maintenance Order: Putting in Process SAP AG 1999 Status 'RELEASED' Order papers Put in process
- 23. 23 Plant Maintenance- Overview Time Confirmations SAP AG 1999 Initial screen Partial confirmation Final confirmation Scope Reversal option Individual entry Collective entry Collective entry using operation list Overall completion confirmation
- 24. 24 Plant Maintenance- Overview Maintenance Order: Technical Completion SAP AG 1999 Order 901760 Limited ability to change order Status 'Technically completed' Define location and account assignment data Create settlement rule Set deletion flag for purchase requisitions Close open reservations Close open capacities
- 25. 25 Plant Maintenance- Overview Cycle for Corrective Maintenance 1 2 3 SAP AG 1999 Notification Planning Scheduling Execution Completion • Technical object • Description • Work to be performed • Internal/external resources History • Date • Malfunction Material usage, orders, notifications, PMIS, usage list • Material • Tools • Capacity leveling • Availability check • Order release • Printout • Planned/unplanned material withdrawal • External procurement • Time confirmation • Technical completion • Order settlement • Technical confirmation 4 5
- 26. 26 Plant Maintenance- Overview Definition of Maintenance Notification SAP AG 1999 Describes the condition of a maintenance object, particularly a malfunction Malfunction report Describes a maintenance activity already performed (purely technical documentation) Activity report Requests a maintenance service/task Maintenance request
- 27. 27 Plant Maintenance- Overview Maintenance Notification: Structure SAP AG 1999 Date / time / reported by Description Object: Functional location Equipment Assembly Material serial number Location data Breakdown / availability Activity Execution factors Activities Dates Task description Tasks Damage location Damage Cause of damage NotifTiceaxttion items Notification
- 28. 28 Plant Maintenance- Overview Maintenance Notification: Object Information SAP AG 1999 Maintenance dates Notifications ii Processing days Object information Documents Links Breakdowns Structure list Orders
- 29. 29 Plant Maintenance- Overview Select Maintenance Notifications Why ? Find particular maintenance notification Process several maintenance notifications simultaneously Restrict planning worklist SAP AG 1999 Different sorting Select / delete complete list Different list fields, internal display variant Display breakdowns graphically Excel processing Scope Notification Notification items Tasks Customizing Selection conditions Field selection Functions
- 30. 30 Plant Maintenance- Overview Print Maintenance Notifications SAP AG 1999 Maintenance notification Notification overview Breakdown report Activity report Fax transfer
- 31. 31 Plant Maintenance- Overview Cycle for Corrective Maintenance 1 3 SAP AG 1999 Notification Scheduling Execution Completion • Technical object • Description • Order release • Printout • Planned/unplanned material withdrawal • External procurement • Time confirmation • Technical completion History • Date • Malfunction • Capacity leveling • Availability check • Order settlement • Technical confirmation Material usage, orders, notifications, PMIS, usage list 4 5 PPllaannnniinngg • Work to be performed • Internal/external resources • Material • Tools 2
- 32. 32 Plant Maintenance- Overview Creation of Maintenance Orders SAP AG 1999 Maintenance order / notification Direct creation of order Maintenance notification Maintenance order Creation of order based on notification Maintenance notification Maintenance item Maintenance order Automatic generation of maintenance order from maintenance item Maintenance notification Maintenance notification Maintenance order Combination of maintenance notifications for maintenance order Maintenance notification Maintenance order Entry of order with subsequent activity report
- 33. 33 Plant Maintenance- Overview Characteristics of Maintenance Orders SAP AG 1999 Flexibility of order processing Object reference Single object Object list Period of validity Single order Standing order Execution Internal processing External processing
- 34. 34 Plant Maintenance- Overview Stock Material - Process Flow Component assignment SAP AG 1999 Material reservation May Availability check Goods issue Printing Order release Automatic availability check May
- 35. 35 Plant Maintenance- Overview Cycle for Corrective Maintenance 1 2 SAP AG 1999 Notification Planning Execution Completion • Technical object • Description • Date • Malfunction • Work to be performed • Internal/external resources History Material usage, orders, notifications, PMIS, usage list • Material • Tools • Planned/unplanned material withdrawal • External procurement • Time confirmation • Technical completion • Order settlement • Technical confirmation 4 5 SScchheedduulliinngg • Capacity leveling • Availability check • Order release • Printout 33
- 36. 36 Plant Maintenance- Overview SAP AG 1999 Stock profile Inward stock movement from purchase order Material withdrawal for cost center Stock transfer to other plant Inward stock movement from internal production Plant stock Today Requirement date Safety stock Maximum ATP quantity Resource Planning: Availability Check
- 37. 37 Plant Maintenance- Overview Maintenance Order: Printing SAP AG 1999 Maintenance order Fax transfer Job ticket Operation control ticket Pick list Material withdrawal slip Confirmation slip Time ticket Object list
- 38. 38 Plant Maintenance- Overview Order Completion Confirmation: Times / Activities SAP AG 1999 Times Individual entry Collective entry Overall completion confirmation Time sheet (CATS) Activities Activity reports Overall completion confirmation Confirmation texts Object changes Measurement readings
- 39. 39 Plant Maintenance- Overview •Questions ?? •Contact Details : mail id : gthangavelu@darylflood.com Cell : 469-879-4674 Residence : 972-444-8510