Uploaded bySubhrajyoti (Subhra) Bhattacharjee
Sap plant maintenance
The document provides an overview of SAP Plant Maintenance (SAP PM) including: 1) It discusses the organizational structure for maintenance planning including centralized vs decentralized structures. 2) It outlines the key master data used in SAP PM such as technical objects, work centers, maintenance plans, and tasks lists. 3) It describes some of the main maintenance processing scenarios in SAP PM like maintenance notifications, maintenance orders, and preventative maintenance planning.
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Sap plant maintenance
- 1. SAP Plant Maintenance Presentation By: Mr. Subhrajyoti Bhattacharjee B.E., P.G.D.M., PMP®, Certified SAP PM Solution Consultant
- 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
- 4. Government & Authorities Vendors Organization Customers Environment
- 5. External Vendors Environment Organizational ERP System Finance & Controllin g Purchasin Projects g Productio n Planning HR & Payroll Sales & Distributio Maintena n nce Government & Customers Authorities
- 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
- 9. Company Centralized Code De-centralized Planning Planning Maintenance Maintenance Planning Planning Plant Plant Maintenance Maintenance Maintenance Plant Plant Plant
- 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
- 11. Technical Objects SAP Work PM: Planning Centres Master Objects Data Others
- 12. Work Centre Work Centre Hierarchy is a Hierarch Grouping of Work centres y comprising Maintenance Task Force Work Capacity Centre Capacity information includes: PM Work Centre Category “0005” Comprises: Basic data, Default values, Capacity Unit of capacity view, Scheduling Start/End times view, HR Assignments, Costing Utilizations view Shift schedules etc.
- 14. Load Monitoring Capacity Planning Capacity Leveling Capacity Functionalities
- 15. Functional Locations Structured into Hierarchical Levels using Structure Indicators Equipment Serial Number Sub Equipment Material No Equipment Bill of Material Component material parts
- 17. Plan Top Down Bottom up planning planning Task List Maintenance item
- 18. • Single cyclePlans • Strategy Based Plans Plans • Counter Based Plans (Single/Multi Counter) • General Task Lists • Functional Location Task Lists Task Lists • Equipment Task Lists • Standard items • Strategy based items Items
- 19. Other Master Data Measuring Points/Counters Class/ Characteristi cs Permits
- 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 Maintenance Orders Notifications are are a complete record Reporting objects to of: record: Operations performed Maintenance requirement Components used Cause, Object (Stock/Non stock) Impacted, Tasks due & Services hired Activities Performed Time and costs posted Types: Maintenance Settlements executed Request, Malfunction (Breakdown) Types: Breakdown Report, Activity Orders, Planned Report, Service Orders, Predictive Notifications Orders, Calibrations Orders, Refurbishment Maintenance Notifications 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. Master Data Functional Material Work center Equipment Location (Stock parts) (PM & PP) Production personnel Permits (If Activity Service follows up on work done against existing applicable) Type Master record Notification Yes Further work done is recorded in SAP Notification mail to Existing Notification Notification& initiator of work (Report IW29)? Notification Tasks Technically completed No No SAP Notification mail to Notification user PM Oredr Maintenance designated Person status changed to Planning done Equipment breaks Convert to PM Order (Type Notification (Type responsible in Yes ALWD and (Operation, down Order? PM01) created “M2”) created Notification header notification Components, released Service, Permits) Shop papers printed from PM order Goods receipt to Storage Issue stock part to Reservation No location assigned to PM Order Stock part Yes Approved purchase Purchase requisitions converted to requisition created Order user status Assigned permits if Is stock part Is Stock part Purchase order (MM side) No Yes changed to PLND any are issued by available? planned? and order released relevant personnel No Approved purchase Purchase Goods receipt against PO requisition requisitions Is Non – stock posts costs to associated converted to created within Yes part planned? PM order Purchase order PM order Y Order settled to relevant No Yes settlement receiver (Cost Center) Approved Service acceptance Purchase purchase throughService entry requisition Is Extenal Is further planning requisitions sheet against Service PO created within service required? converted to posts costs to associated PM order planned? Purchase order PM order No Production Settlement rule defined in User status of personnel to Time confirmation order & Order Technically Maintenance order confirm Order for Manhours with Is Maintenance completed with details of changed to MTCO – Yes No completion by suitable Activity work completed? Malfunction end date/time Completed by changing user Type status to PRCO Maintenance In SAP Outside SAP
- 27. Master Data Functional Material Work center Service Equipment Location (Stock parts) (PM & PP) Master record Counter (For Permits (If Activity Maintenance Maintenance counter based applicable) Type Task List Plan plans) Measurement Planned Due document posting dates for order for Counter Based creation are set in plans system Orders generated Maintenance Plan Scheduling overview for the periodare Maintenance plan Is next call object – Preventive created (Single report generated by planned further Maintenance Task cycle/Strategy scheduled Maintenance Order Yes Maintenance order maintenance List created (Background job/ due? (Type”PM02") (Operation, based/Counter personnel on a Components, Manual) generated based) periodic basis Service, Permits) Shop papers printed from PM order Goods receipt to Storage Issue stock part to Reservation No location assigned to PM Order Stock part Yes Approved purchase Purchase requisitions converted to requisition created Order user status Assigned permits if Is stock part Is Stock part Purchase order (MM side) No Yes changed to PLND any are issued by available? planned? and order released relevant personnel No Approved Purchase purchase Goods receipt against PO requisition requisitions Is Non – stock posts costs to associated created within Yes converted to part planned? PM order PM order Purchase order Y Order settled to relevant No Yes settlement receiver (Cost Center) Approved Service acceptance purchase Purchase throughService entry requisitions requisition Is Extenal Is further planning sheet against Service PO converted to created within service required? posts costs to associated Purchase order PM order planned? PM order No Production Settlement rule defined in User status of personnel to Time confirmation order & Order Technically Maintenance order confirm Order for Manhours with Is Maintenance completed with details of changed to MTCO – Yes No completion by suitable Activity work completed? Start/end date/time Completed by changing user Type status to PRCO Maintenance In SAP Outside SAP
- 28. Master Data Functional Material Work center Service Equipment Location (Stock parts) (PM & PP) Master record Counter (For Permits (If Activity Maintenance Maintenance counter based applicable) Type Task List Plan plans) Measurement Planned Due document posting dates for order for Counter Based creation are set in plans system Maintenance Task Maintenance Plan Scheduling overview Calibration Orders auto Maintenance plan Is next call object – Preventive List created created (Single report generated by generated and released (Inspection point cycle/Strategy scheduled Maintenance Order Yes Maintenance order maintenance (Operation, (Background job/ due? (Type”PM02") 300, MIC’s based/Counter personnel on a Components, Service, Manual) generated entered) based) periodic basis Permits) Goods receipt to Storage Issue stock part to Reservation No location assigned to PM Order Stock part Yes Shop papers printed from PM order Approved purchase Purchase requisitions converted to requisition created Quality Inspection Lot Is stock part Is Stock part Purchase order (MM side) No Yes Generated available? planned? Order settled to relevant No settlement receiver (Quality Cost Center) Approved Purchase purchase Goods receipt against PO requisition requisitions Is Non – stock posts costs to associated created within Yes converted to part planned? PM order PM order Purchase order Y No Yes Result recording done Approved against Inspection Lot, Order Service acceptance purchase Purchase Technically completed throughService entry requisitions requisition Is Extenal Is further planning sheet against Service PO converted to created within service required? posts costs to associated Purchase order PM order planned? PM order No Time confirmation for Internal Settlement rule set in Is Maintenance Manhours with Yes No Calibration order work completed? suitable Activity Type In SAP Outside SAP
- 29. Master Data Functional Material Work center Equipment Location (Stock parts) (PM & PP) Permits (If Activity Service Requestor checks on work progress applicable) Type Master record Yes Work detailed in SAP Notification mail to Notification and Tasks Existing Notification initiator of work Technically completed (Report IW29)? No No Notification user PM Oredr Scope for correction/ Maintenance SAP Notification mail to status changed to Planning done predictive maintenance Notification (Type designated Person Convert to PM Order (Type Yes ALWD and (Operation, identified by Operator/ “M1” Maintenance responsible in Order? PM01) created notification Components, Maintenance person request) created Notification header released Service, Permits) Shop papers printed from PM order Goods receipt to Storage Issue stock part to Reservation No location assigned to PM Order Stock part Yes Approved purchase Purchase requisitions converted to requisition created Order user status Assigned permits if Is stock part Is Stock part Purchase order (MM side) No Yes changed to PLND any are issued by available? planned? and order released relevant personnel No Approved Purchase purchase Goods receipt against PO requisition requisitions Is Non – stock posts costs to associated created within Yes converted to part planned? PM order PM order Purchase order Y Order settled to relevant No Yes settlement receiver (Cost Center) Approved Service acceptance purchase Purchase throughService entry requisitions requisition Is Extenal Is further planning sheet against Service PO converted to created within service required? posts costs to associated Purchase order PM order planned? PM order No Production Settlement rule defined in User status of personnel to Time confirmation order & Order Technically Maintenance order confirm Order for Manhours with Is Maintenance completed with details of changed to MTCO – Yes No completion by suitable Activity work completed? Start/ end date/time Completed by changing user Type status to PRCO Maintenance In SAP Outside SAP
- 30. Master Data Asset Master – Functional Material Work center AuC/FxA (As Location (Stock parts) (PM & PP) relevant) Permits (If Activity Service Equipment applicable) Type Master record (Associated to FxA) Asset under Maintenance Team Functional Location (for asset construction created intimated on the AuC build up created) as reference New Asset buildup by Business SAP Number Technical object Finance Team Capital work – New asset build up or Enhancement Order Planning Capital work Order (Type done (Operation, Existing Equipment No (with “PM06”) created – with Components, Asset Enhancement assigned Fixed asset) would relevant Maintenance Service, Permits), be identified Activity type assigned Settlement rule defined Shop papers printed from PM order Goods receipt to Storage Issue stock part to Reservation No location assigned to PM Order Yes Stock part Functional Location Structure Approved purchase Purchase requisitions converted to requisition created Is stock part Assigned permits if completed with assigned No Is Stock part Capital order Purchase order (MM side) available? Yes any are issued by Equipment tagged to FxA planned? released relevant personnel number No Approved Purchase purchase Maintenance Team Goods receipt against PO requisition intimated on the FxA requisitions Is Non – stock posts costs to associated created within Yes converted to part planned? Number PM order PM order Purchase order Y No Yes Approved Service acceptance Purchase In case of Asset buildup work, purchase throughService entry requisition Is Extenal Is further planning Finance finally settles AuC to requisitions sheet against Service PO created within Yes service required? a FxA ( created) converted to posts costs to associated PM order planned? Purchase order PM order No Time confirmation On completion of work Order Periodic settlement for Manhours with Is Maintenance Technically completed with executed to relevant Yes No suitable Activity work completed? necessary details receiver (AuC/FxA) Type In SAP Outside SAP
- 31. Master Data Ref. Material (with PM Work center valuation types Serial Equipment (For Internal C1, C2, C3) Number Refurbishment) Batch Numbers for C1, Asset No Service Activity C2, C3 states of Ref (Tagged to material Master record Type Equipment ID) Refurbishment order type Order Planning done “PM04" created for Material (Operation – Internal or Need for Refurbishment No, to convert from C3 - External Services, Additional identified Damaged to C2 - Components if any), Refurbished state Settlement rule defined Shop papers printed from PM order Goods receipt to Storage Issue stock part to Reservation No location assigned to PM Order Stock part Yes Approved purchase Purchase Additional requisitions converted to requisition created Damaged Material part Available in Stock parts Order released Purchase order (MM side) No Yes (valuation type C3) issued to stock? required/ reservation no. in order planned? No Approved Purchase purchase Goods receipt against PO requisition requisitions Is Non – stock posts costs to associated created within Yes converted to part planned? PM order PM order Purchase order Y No Yes Approved Service acceptance Purchase Settlement executed to settle purchase Is Extenal throughService entry requisition Is further planning order costs (As per business requisitions Refurbishment sheet against Service PO created within required? requirement to FxA) converted to service posts costs to associated PM order Purchase order planned? PM order No Time confirmation for Manhours with On completion of work Order Goods receipt of suitable Activity Is Maintenance Technically completed with Refurbished part (val. Type Yes No Type – In case of work completed? necessary details “C2") to store internal manhour consumed In SAP Outside SAP
- 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. Plant Maintenance Controlling QM Master Employe Equipments e Sender Cost Activity Functional Planned Notification PM Work Center Types Location Rates /hr Financial Center Accounting Receiver Cost Center Maintenance Order G/L Fixed Equipment Plan Header Account Asset Material Management Operation - Internal Shutdown Operation – Services Service Master PP Work BOM Spares Compone Center - nt Machine Material Master Costs
- 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. SCADA SAP BW SAP Plant Maintenance Others SAP MI
- 37. Maintenance Cost AnalysisReport Wave- I Wave- II
- 38. Man hour UtilizationReport Wave- I Wave- II
- 39. Downtime Analysis Report Wave- I Wave- II
- 40. MTTR/MTBF Report Wave- I Wave- II
- 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
- 44.