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Sap plant maintenance
- 1. Presentation By: Mr. SubhrajyotiBhattacharjee B.E., P.G.D.M., PMP®, Certified SAP PM Solution Consultant SAP Plant Maintenance
- 2. Brief Background ofPresenter Subhra works as SAP Systems Analyst at Iluka Resources Limited, Perth, Western Australia He has a Net experience of around 7.8 years with around 6 years of SAP Consulting Experience in SAP PM & CS, MM modules. He has also has standard configuration knowledge of SAP PS, DMS and integration aspects of other SAP modules & applications He has worked in multiple SAP Implementation, Upgrade, Support & Audit assignments in Australia, USA, India and Middle East and is an ex-employee of PwC India Ltd, T.C.S. Limited He also possesses Core Industry experience of 1.8 years in Maintenance & Inbound Logistics
- 3. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Advanced scenarios, Interfaces & Reports
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- 5. Organizational ERP System Purchasin g Sales & Distributio n Projects Government& Authorities Productio n Planning Vendors Customers External Environment Finance & Controllin g HR & Payroll Maintena nce
- 6. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Advanced scenarios, Interfaces & Reports
- 7. Maintenance isa Support Function within an Organization and Maintenance costs generally constitute a part of Production overhead costs except when Maintenance is carried out on Customer Assets to earn revenue. Primary Objective of Maintenance is to maintain a high level of Availability, preventing degeneration and maintaining optimal utilization life of an Organization’s Physical Assets. Physical Assets primarily comprise: Fixed assets such as Plant & Machinery, Buildings & Properties, Vehicles and so on. Usually such assets have a Long useful life (usually > 1 year) over which they are depreciated Operating Assets which may not be treated as Assets in Financial Module nor depreciated, but having a long term utilization High valued current assets such as High valued spares/operating supplies/machine parts which are subject to Refurbishments with their condition based values maintained accurately Key Performance objectives in Maintenance include Maintaining a high level of OEE (Overall Equipment Effectiveness) Maintaining and Optimal balance between Cost of Breakdown vs. Cost of Prevention Utilizing concepts such as TPM, RCM etc. to contribute in Lowering Operating costs and minimize adverse effects on Equipment ,Operating resources and
- 8. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Advanced scenarios, Interfaces & Reports
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- 10. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Advanced scenarios, Interfaces & Reports
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- 12. Capacity information includes: Unit of capacity Start/Endtimes Utilizations Shift schedules etc. Capacity PM Work Centre Category “0005” Comprises: Basic data, Default values, Capacity view, Scheduling view, HR Assignments, Costing view Work Centre Work Centre Hierarch y Work Centre Hierarchy is a Grouping of Work centres comprising Maintenance Task Force
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- 15. FunctionalLocations Equipment SubEquipment EquipmentBillofMaterial Componentmaterialparts Serial Number Material No Structuredinto Hierarchical Levels using Structure Indicators
- 17. Plan Task List Maintenance item Bottomup planning Top Down planning
- 18. Plans • Single cyclePlans • Strategy Based Plans • Counter Based Plans (Single/Multi Counter) Task Lists • General Task Lists • Functional Location Task Lists • Equipment Task Lists Items • Standard items • Strategy based items
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- 20. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Advanced scenarios, Interfaces & Reports
- 21. Maintenance Notifications vs.Maintenance Orders Maintenance Notifications are Reporting objects to record: Maintenance requirement Cause, Object Impacted, Tasks due & Activities Performed Types: Maintenance Request, Malfunction (Breakdown) Report, Activity Report, Service Notifications Maintenance Notifications generally do not record Maintenance Orders are a complete record of: Operations performed Components used (Stock/Non stock) Services hired Time and costs posted Settlements executed Types: Breakdown Orders, Planned Orders, Predictive Orders, Calibrations Orders, Refurbishment Orders, Capital Work
- 24. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Advanced scenarios, Interfaces & Reports
- 26. Order (Type PM01) created Convertto PM Order? Assigned permits if any are issued by relevant personnel Is stock part available? Purchase requisition created (MM side) Approved purchase requisitions converted to Purchase order Yes YesNo Notification user status changed to ALWD and notification released PM Oredr Planning done (Operation, Components, Service, Permits) Order user status changed to PLND and order released No Stock part Y Issue stock part to Reservation No assigned to PM Order Master Data Functional Location Equipment Material (Stock parts) Permits (If applicable) Activity Type Equipment breaks down Shoppapers printedfrom PMorder No In SAP Outside SAP Service Master record Work center (PM & PP) Maintenance Notification (Type “M2”) created Existing Notification (Report IW29)? No Production personnel follows up on work done against existing Notification Yes Yes Is Stock part planned? No Goods receipt to Storage location Is Non – stock part planned? Is Extenal service planned? Purchase requisition created within PM order Yes Approved purchase requisitions converted to Purchase order Goods receipt against PO posts costs to associated PM order Purchase requisition created within PM order Approved purchase requisitions converted to Purchase order Service acceptance throughService entry sheet against Service PO posts costs to associated PM order Is Maintenance work completed? User status of Maintenance order changed to MTCO – Completed by Maintenance Yes Is further planning required? Yes No Production personnel to confirm Order completion by changing user status to PRCO Time confirmation for Manhours with suitable Activity Type Settlement rule defined in order & Order Technically completed with details of Malfunction end date/time Order settled to relevant settlement receiver (Cost Center) Further work done is recorded in Notification& Notification Tasks Technically completed No SAP Notification mail to designated Person responsible in Notification header SAP Notification mail to initiator of work
- 27. Scheduling overview report generatedby maintenance personnel on a periodic basis Assigned permits if any are issued by relevant personnel Is stock part available? Purchase requisition created (MM side) Approved purchase requisitions converted to Purchase order YesNo Preventive Maintenance order (Type”PM02") generated Orders generated for the periodare planned further (Operation, Components, Service, Permits) Order user status changed to PLND and order released No Stock part Y Issue stock part to Reservation No assigned to PM Order Master Data Functional Location Equipment Material (Stock parts) Permits (If applicable) Activity Type Yes Shoppapers printedfrom PMorder No In SAP Outside SAP Maintenance Task List Work center (PM & PP) Is next call object – Maintenance Order due? Yes Is Stock part planned? No Goods receipt to Storage location Is Non – stock part planned? Is Extenal service planned? Purchase requisition created within PM order Yes Approved purchase requisitions converted to Purchase order Goods receipt against PO posts costs to associated PM order Purchase requisition created within PM order Approved purchase requisitions converted to Purchase order Service acceptance throughService entry sheet against Service PO posts costs to associated PM order Is Maintenance work completed? User status of Maintenance order changed to MTCO – Completed by Maintenance Yes Is further planning required? Yes No Production personnel to confirm Order completion by changing user status to PRCO Time confirmation for Manhours with suitable Activity Type Settlement rule defined in order & Order Technically completed with details of Start/end date/time Order settled to relevant settlement receiver (Cost Center) Service Master record Maintenance Plan Counter (For counter based plans) Maintenance Task List created Maintenance Plan created (Single cycle/Strategy based/Counter based) Maintenance plan scheduled (Background job/ Manual) Measurement document posting for Counter Based plans Planned Due dates for order creation are set in system
- 28. Scheduling overview report generatedby maintenance personnel on a periodic basis Is stock part available? Purchase requisition created (MM side) Approved purchase requisitions converted to Purchase order YesNo Preventive Maintenance order (Type”PM02") generated Calibration Orders auto generated and released (Operation, Components, Service, Permits) No Stock part Y Issue stock part to Reservation No assigned to PM Order Master Data Functional Location Equipment Material (Stock parts) Permits (If applicable) Activity Type Yes Shoppapers printedfrom PMorder No In SAP Outside SAP Maintenance Task List Work center (PM & PP) Is next call object – Maintenance Order due? Yes Is Stock part planned? No Goods receipt to Storage location Is Non – stock part planned? Is Extenal service planned? Purchase requisition created within PM order Yes Approved purchase requisitions converted to Purchase order Goods receipt against PO posts costs to associated PM order Purchase requisition created within PM order Approved purchase requisitions converted to Purchase order Service acceptance throughService entry sheet against Service PO posts costs to associated PM order Is Maintenance work completed? Yes Is further planning required? Yes No Time confirmation for Internal Manhours with suitable Activity Type Settlement rule set in Calibration order Service Master record Maintenance Plan Counter (For counter based plans) Maintenance Task List created (Inspection point 300, MIC’s entered) Maintenance Plan created (Single cycle/Strategy based/Counter based) Maintenance plan scheduled (Background job/ Manual) Measurement document posting for Counter Based plans Planned Due dates for order creation are set in system Quality Inspection Lot Generated Result recording done against Inspection Lot, Order Technically completed Order settled to relevant settlement receiver (Quality Cost Center)
- 29. Order (Type PM01) created Convertto PM Order? Assigned permits if any are issued by relevant personnel Is stock part available? Purchase requisition created (MM side) Approved purchase requisitions converted to Purchase order Yes YesNo Notification user status changed to ALWD and notification released PM Oredr Planning done (Operation, Components, Service, Permits) Order user status changed to PLND and order released No Stock part Y Issue stock part to Reservation No assigned to PM Order Master Data Functional Location Equipment Material (Stock parts) Permits (If applicable) Activity Type Scope for correction/ predictive maintenance identified by Operator/ Maintenance person Shoppapers printedfrom PMorder No In SAP Outside SAP Service Master record Work center (PM & PP) Maintenance Notification (Type “M1” Maintenance request) created Existing Notification (Report IW29)? No Requestor checks on work progress Yes Yes Is Stock part planned? No Goods receipt to Storage location Is Non – stock part planned? Is Extenal service planned? Purchase requisition created within PM order Yes Approved purchase requisitions converted to Purchase order Goods receipt against PO posts costs to associated PM order Purchase requisition created within PM order Approved purchase requisitions converted to Purchase order Service acceptance throughService entry sheet against Service PO posts costs to associated PM order Is Maintenance work completed? User status of Maintenance order changed to MTCO – Completed by Maintenance Yes Is further planning required? Yes No Production personnel to confirm Order completion by changing user status to PRCO Time confirmation for Manhours with suitable Activity Type Settlement rule defined in order & Order Technically completed with details of Start/ end date/time Order settled to relevant settlement receiver (Cost Center) SAP Notification mail to initiator of work Work detailed in Notification and Tasks Technically completed SAP Notification mail to designated Person responsible in Notification header No
- 30. Capital work Order(Type “PM06”) created – with relevant Maintenance Activity type assigned Assigned permits if any are issued by relevant personnel Is stock part available? Purchase requisition created (MM side) Approved purchase requisitions converted to Purchase order YesNo Order Planning done (Operation, Components, Service, Permits), Settlement rule defined Capital order released No Stock part Y Issue stock part to Reservation No assigned to PM Order Master Data Functional Location Asset Master – AuC/FxA (As relevant) Material (Stock parts) Permits (If applicable) Activity Type Shoppapers printedfrom PMorder No In SAP Outside SAP Service Master record Work center (PM & PP) Yes Is Stock part planned? No Goods receipt to Storage location Is Non – stock part planned? Is Extenal service planned? Purchase requisition created within PM order Yes Approved purchase requisitions converted to Purchase order Goods receipt against PO posts costs to associated PM order Purchase requisition created within PM order Approved purchase requisitions converted to Purchase order Yes Service acceptance throughService entry sheet against Service PO posts costs to associated PM order Is Maintenance work completed? Yes Is further planning required? Yes No Time confirmation for Manhours with suitable Activity Type Periodic settlement executed to relevant receiver (AuC/FxA) Asset under construction created by Business SAP Finance Team Maintenance Team intimated on the AuC Number Capital work – New asset build up or Enhancement New Asset buildup Existing Equipment No (with assigned Fixed asset) would be identified Asset Enhancement Functional Location (for asset build up created) as reference Technical object Equipment (Associated to FxA) On completion of work Order Technically completed with necessary details In case of Asset buildup work, Finance finally settles AuC to a FxA ( created) Maintenance Team intimated on the FxA Number Functional Location Structure completed with assigned Equipment tagged to FxA number
- 31. Refurbishment order type “PM04"created for Material No, to convert from C3 - Damaged to C2 - Refurbished state Purchase requisition created (MM side) Approved purchase requisitions converted to Purchase order Yes Order Planning done (Operation – Internal or External Services, Additional Components if any), Settlement rule defined No Stock part Y Issue stock part to Reservation No assigned to PM Order Master Data Serial Number Equipment Activity Type Shoppapers printedfrom PMorder No In SAP Outside SAP Service Master record PM Work center (For Internal Refurbishment) Additional Stock parts required/ planned? No Goods receipt to Storage location Is Non – stock part planned? Is Extenal Refurbishment service planned? Purchase requisition created within PM order Yes Approved purchase requisitions converted to Purchase order Goods receipt against PO posts costs to associated PM order Purchase requisition created within PM order Approved purchase requisitions converted to Purchase order Service acceptance throughService entry sheet against Service PO posts costs to associated PM order Is Maintenance work completed? Yes Is further planning required? Yes No Time confirmation for Manhours with suitable Activity Type – In case of internal manhour consumed Goods receipt of Refurbished part (val. Type “C2") to store Need for Refurbishment identified Asset No (Tagged to Equipment ID) On completion of work Order Technically completed with necessary details Settlement executed to settle order costs (As per business requirement to FxA) Ref. Material (with valuation types C1, C2, C3) Batch Numbers for C1, C2, C3 states of Ref material Damaged Material part (valuation type C3) issued to reservation no. in order Order releasedAvailable in stock? No Yes
- 32. ERP Systems: AnOverview Plant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: Objects Maintenance Processing: Scenarios Integrations, Advanced scenarios, Interfaces & Reports
- 33. Equipment Functional Location Fixed Asset BOM SparesPP Work Center- Machine Plant Maintenance Financial Accounting PM Work Center Order Header Operation - Internal Compone nt Operation – Services Shutdown Notification Maintenance Plan Costs Material Master Service Master Material Management Controlling Activity Types Sender Cost Center Receiver Cost Center QM Master Equipments Employe e Planned Rates /hr G/L Account
- 34. PM -Customer Service Scenarios PM - Work Clearance Management PM – Fleet Management PM – Mobile Asset Management ** PM – Project Oriented Maintenance ** PM – Linear Asset Management ** PM – Rotables Subcontracting ** PM – Inspection Rounds ** PM – Take over- Hand over of Equipments ** Functionalities available only in ECC 6.0 and in specific EHP versions
- 35. SAP Plant Maintenance SCADA SAPMI SAP BW Others
- 37. Maintenance Cost AnalysisReport Wave- I Wave- II
- 38. Man hour UtilizationReport Wave- I Wave- II
- 39. Downtime Analysis Report Wave-I Wave- II
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- 41. Cause and EffectAnalysis Report Wave- I Wave- II
- 42. Preventive Schedule OverviewReport Wave- I Wave- II
- 43. Material Goods Movement/ConsumptionReport Wave- I Wave- II
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