Downloaded 446 times
More Related Content
Similar to SAP PM Plant Maintenance Training
SAP PM Plant Maintenance Training
- 1.
- 2. Organizational Structures inPM Client Storage location e.g. Spare parts warehouse e.g. Production plant e.g. International subsidiary e.g. Production area, plant engineering Maintenance plant PM planning plant Location Plant section PM planner group PM work centers e.g. Plant with technical system e.g. Area, buildings e.g. Plant with PM planning e.g. Foreman, work scheduler e.g. Mechanics, electronics General organizational units Location-based organizational units Planning-based organizational units Plant Company code e.g. Corporate group
- 3. Organization of MaintenancePlanning Plant 1000 Plant 1200 Plant 1300 Workshops Workshops Maintenance requirement Maintenance requirement Maintenance requirement Maintenance requirement Planning of maintenance requirements Planning of maintenance requirements Maintenance requirement Maintenance requirement Material Warehouse
- 4. The following scenarioscan be made in SAP 01. Notification 02. Maintenance Order 03. Maintenance Task list 04. Maintenance plan 05. Conformation/TECO of maintenance orders 06. Settlement of order 07. Spare parts Management 08. Work Permits 09. Warranty 10. Measuring point and Measuring documents 11. Calibration of instruments
- 5. Master Data To performthe above scenarios the following Master data are most important in SAP R/3 01. Functional location 02. Equipment 03. Bill of Materials 04. Maintenance Work Center 05. Maintenance Task List 06. Class and Characteristics 07. Maintenance Plan/ Scheduling 08. Catalog (Object part, Damage, Cause, Code, Task, Activity) Cont.
- 6. 09. Measuring point/ Measurement document 10. PRT - Production Resource Tool NOTE--only if master data is accurately maintained, you will stand to gain by getting very useful standard report for your effective analysis and make your working life enjoyable.!!! Master Data
- 7.
- 8. The workcenter is an organizational unit that contains group of resources who can perform work It specifies where and by whom the operations can be performed. Machines, people, groups of people and so on, can be defined as work centers. The work center is an organizational unit that contains group of resources who can perform work It specifies where and by whom the operations can be performed. Machines, people, groups of people and so on, can be defined as work centers. DefinitionDefinitionDefinitionDefinition Work Center
- 9.
- 10. Functional Locations The functionallocation is an organizational unit, that structures the maintenance objects of a company according to three types 1. Functional 2. Process-related 3. Spatial criteria. A functional location represents the place at which a maintenance task is to be performed. A functional location represents system area at which an object can be installed. The objects that can be installed at functional locations are called equipment in the SAP R/3 System
- 11. Functional Locations technical functional spatial Multi-level hierarchiesStructure technical systems based on Criteria
- 12. Example of aFL Structure C1-B Biological purification C1C1 Clarification plantClarification 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 purification 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 Filter 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
- 13. Edit maskEdit mask HierarchylevelsHierarchy levels A = Alpha N = Numeric X = Alphanumeric System Area Sub-area Function Sub-function Item Location numberLocation number A1 A1-B A1-B02 A1-B02- 9 A1-B02- 9-C A1-B02- 9-C- 1 1 2 3 4 5 6 AN-ANN-N-X-X Structure Indicator
- 14.
- 15. Equipment Individual, physical objectthat is to be maintained as an autonomous unit. Equipment can be installed and dismantled at functional locations. •Perform individual maintenance tasks for the equipment •Keep a record of the maintenance tasks performed for the equipment •Collect and evaluate data over a long period of time for the equipment •The costs of maintenance tasks can be monitored for the Equipment
- 16. Installation/Dismantling of Equipment Functionallocation Equipment
- 17. History of DocumentChanges which SAP tracks Documents Classification Measuring point Long text Installation location Permits Addresses Documents Classification Measuring point Long text Installation location Permits Addresses
- 18. Bill of Material- BOM
- 19. Components (Spare Parts)/ Bill of Materials A maintenance bill of material (BOM) is a complete, structured list of the components making up a Equipment. The list contains the quantity and unit of measure of the components. The components can be stock or non-stock spares.
- 20. Material BOMMaterial masterrecord Equipment BOM Functional location BOM Equipment master record Functional location master record Material Bill of Material Categories
- 21.
- 22. ROH - RawMaterials HALB - Semi finished Products FERT - Finished Product ERSA - Spare Parts HIBE - Operating Supplies Maintenance Assembly For Plant Maintenance Type of Materials
- 23. Initial screen 1 1.Partno 2. Industry Sector 3. Material Type
- 24. Initial screen 2 1.Plant 2.Storage Location
- 25.
- 26. PressurePressure 1010 2020 3030 4040 5050 6060 7070 8080 22 33 5511 KilometersKilometers TemperatureTemperature 00 11 22 77 55 Operating hrsOperating hrs Measuring Points and Counters
- 27. Meas. Doc. 1010 2020 3030 40405050 6060 7070 8080 0011227755 22335511 Meas. Doc. Meas. Doc. Temperature 60 °C Kilometers 2351 Operating hours 01275 Meas. Doc. Pressure 58 Pascal Entering Measurement and Counter Readings
- 28.
- 29. PRT (Production Resource Tools) Toperform Planned/ Breakdown Maintenance works, some resources are required. These resources are given the term production resources/tools (abbreviated to PRT ) in SAP. PRT can be Equipment, Documents and Materials. Eg: Welding Machine, Megger
- 30. Class and characteristics FunctionalLocations and Equipment can both be further detailed using Classifications functionality. Classifications are split into two separate functions: Class - Grouping of data items such as functional location, equipment etc - Ex : Computer , Valves, Pressure gauge - Class specific characteristics can be assigned Characteristics - Describes the attributes of the technical object
- 31. NOTIFICATION • Notification isa intimation to start a maintenance activity • For Breakdown maintenance business process Notification is mandatory • Notification does’nt have link with Material or Finance.
- 32. Notification type Notification type M1 - Maintenancerequest To carry general Maintenance activity M2 - Malfunction report To carry maintenance for Malfunction which is affecting business. M3 - Activity report Carried to recored a activity that is Completed Notification Type
- 33. PrioritiesPriorities 1 2 . . . 1 2 . . . Relevant start and unit Relevant start and unit Relevant end andunit Relevant end and unit PRIORITY Thork Order has a Priority field that indicates the urgency of the work. The Work Order has a Priority field that indicates the urgency of the work and updates date accordingly. The periodization has to be done in the notification before creating the Work Order. A change later on in the Work Order will not change the Dates in notification The following priorities are defined as GAME work order priorities: Routine Work Level 1 2 Weeks – 4 Weeks Routine Work Level 2 4 Weeks – 6 Weeks Routine Work Level 3 6 Weeks – 10 Weeks Routine Work Level 4 8 Weeks – 14 Weeks –The phas to be done in the
- 34. Create PM Notification:Malfunction Report Notification 100123 M2 Status MOFN Order Items Notification Activity categoryActivity category Notification typeNotification type Origin indicatorOrigin indicator Catalog profileCatalog profile PriorityPriority Application component Application component Fields are controlled using Field selection Fields are controlled using Field selection Field Selection for Notifications: Influences
- 35. Electrical work Mechanical tasks . . . Electricalwork Mechanical tasks . . . Code groupsCode groups Replace cable Replace fuse Replace starter Replace cable Replace fuse Replace starter CodesCodes Tasks Causes of damage Activities Object parts Damage Tasks Causes of damage Activities Object parts Damage Catalog typesCatalog types Selection sets of Codes Mandatory evaluation Administrative data Selection sets of Codes Mandatory evaluation Administrative data Catalogs
- 36. Problems: C Causes: 5 Tasks:2 Activities: A Object parts: B Problems: C Causes: 5 Tasks: 2 Activities: A Object parts: B Notification type M2Notification type M2 CC Catalogs Assigning Catalogs to Notification Types 22 55
- 37. PM catalog type Damage Task Objectpart PM catalog type Damage Task Object part Catalog profileCatalog profile Code group 001 1000 002 5400 M* GEN Assigning Catalog Profiles to Notification Types Maintenance Notification Notification typeNotification typeNotification typeNotification type
- 38. MAINTENACE ORDER • Maintenanceorder is also called work order process which is the different maintenance business process/flow carried by business.
- 39. Order Category, OrderType Order typeOrder typeOrder typeOrder type PM01 – Preventive Maintenance order PM02 - Breakdown maintenance order PM03 – Corrective maintenance order PM04 – Calibration order PM05 – Refurbishment order
- 40. Business process inPM CORRECTIVE MAINTENANCE a not This maintenance is a not a planned maintenance can be done at any required time when there is a corrective maintenance activity required.aintenancanbe done at any required time when PREEVNTIVE MAINTENANCE This is carried as preplanned maintenance to avoid breakdown.eakd BREAKDOWN PROCESS This maintenance is carried when a breakdown had happened and business loss involved is CALIBRATION PROCESS The objective of a calibration inspection is to determine whether each piece of equipment specified in the maintenance order meets the predefined performance specification REFURBSIHMENT PROCESS The process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You can define a Refurbishment order as Maintenance order by which you can execute the process of refurbishing damaged equipment. process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You
- 41. GENERAL MAINTENANCE a notThis maintenance is a not a planned maintenance can be done at any required time as a unplanned routine maintenance ntenancanoat any required time when . process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You can define a Refurbishment order as Maintenance order by which you can execute the process of refurbishing damaged equipment
- 42. CORRECTIVE MAINTENANCE a notThis maintenance is a not a planned maintenance can be done at any required time when there is a corrective maintenance activity required To solve the issueintenancanoat any required time when . process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You can define a Refurbishment order as Maintenance order by which you can execute the process of refurbishing damaged equipment
- 43. BREAKDOWN MAINTENANCE a notbrThis break down maintenance is a not a planned maintenance can be done at when business process disturbed or production loss involved. with . process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You can define a Refurbishment order as Maintenance order by which you can execute the process of refurbishing damaged equipment Notification
- 44. How do Iorganize the maintenance of my test equipment? ----1----2----3----4----5 Quantitative Qualitative Inspection interval: Every 78 weeks Cutting length: Diameter of probe pin: Measuring edge 10.087 0.01 2.9 0.03 Sharp Characteristics: Maintenance Plan-Based Test Equipment Management Calibration
- 45. Equipment Task List Maintenance Plan Equipment Master Calibration Order created PM Inspection lotcreated Calibration Inspection Result recording Defects recording Usage Decision Calibration History in SAP Notification Calibration inspection
- 46. REFURBISHMENT PROCESS a notRefurbishment of repairable spares is widely used in process industry, oil producing and processing, steel processing. It is very important to make repairable spares a high level system availability in plant maintenance.These repairable spares of above industory are often the core process in industry process and have high value. So it is more cost-effective to do refurbishment than a brand new purchase. with . process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You can define a Refurbishment order as Maintenance order by which you can execute the process of refurbishing damaged equipment
- 47.
- 48. Maintenance task listsdescribe a sequence of individual maintenance activities which must be performed repeatedly. There are three types of maintenance task lists that can be distinguished from one another : • Equipment Task List • Functional Location Task List • General Maintenance Task List The most important elements are: •Operations (activities) •Sub-operations (Sub-activities) •Material (Components) for individual activities •Maintenance Packages •No. of persons & Time •Production Resources/Tools Task List
- 49. EE Equipment tasklistEquipment task list General maintenance task listGeneral maintenance task listGG FF Functional location task list Maintenance Task List Types
- 50. Internal number assignment Internal number assignment Internaland external Number assignment Task list group Counter Pump_Wtg 01 02 03 04 Pump_Wtg 200125 Equipment Task list group Counter 395 01 02 03 04 Task list group Counter 742 01 02 03 K1-M01 Functional location Maintenance Task Lists: Number Assignment
- 51.
- 52. Maintenance Plan: Functions Cyclestart Cycle Call date Orders/ Inspection Lot Notifications Service entry sheetService entry sheet Electrical work Sanitation work02 01 Service entry sheets Maintenance plan Scheduling data Maintenance item Order 901762 Order 901761 Order 901760 Notificat ion Notificat ionNotificat ion
- 53. Time-based Performance-based Strategy plan Maintenanceplan Single cycle plan Multiple counter plan1 Overview: Maintenance Plans
- 54. Responsibilities / Planning data Referenceobject Task list 3 months Interval (cycle) Maintenance itemMaintenance item Maintenance plan Scheduling data Maintenance item Single Cycle Maintenance Plan
- 55. Maintenance Plan withTask List Maintenance plan Scheduling data Maintenance item Task listTask list 0010 Switch off 0020 Safety check 0030 External visual check 0040 Exchange special seal 0050 Fit casing H9 0060 Check ring Z7
- 56. Manual call Manual call StartStart ScheduleSchedule Last actual date Cyclestart Start date RestartRestart New Cycle start Scheduling Functions - Single Cycle Plan
- 57. 15.03.2000 15.06.2000 = Planneddates Orders for the next 90 days Deadline Monitoring = Scheduling periodDay of execution Order Order 901760 Order 15.09.2000 15.12.2000 Deadline Monitoring
- 58. Which parts mustbe maintained at what intervals? External visual inspection 1 month 1 month Internal visual inspection 3 months 3 months Check gear teeth for wear 1 year 1 year Maintenance Planning with Strategy
- 59. Maintenance Strategy 1997 Scheduling indicator Time- using key date Package definitio 3 months 3 months 6 months 12 months Strategy
- 60. 3 months 3 months Packagenumber Description Cycle length Unit of measurement Hierarchy Offset Preliminary / follow-up buffer Maintenance Package
- 61. 6 months 6 months 3months 3 months 3 months 3 months 6 months 3 months Strategy 0010 Switch off0010 Switch off 0020 Safety check0020 Safety check 0030 External visual check0030 External visual check 0040 Exchange special seal0040 Exchange special seal 0050 Fit casing H90050 Fit casing H9 0060 Check ring Z70060 Check ring Z7 Task list Task List and Maintenance Strategy
- 62. The engine shouldbe changed after 18,000 flying hours or after 12,000 take-offs...and landings. Flying hoursFlying hours Number of take-offs / landingsNumber of take-offs / landings 00015600 00001995 Multiple Counter Plan
- 63. Preventive Maintenance: Phasesand Roles Maintenance technician Maintenance technician Maintenance order Maintenance order Process maintenance ordersProcess maintenance orders44 Maintenance planner Maintenance planner Maintenance planner Maintenance planner Maintenance supervisor Maintenance supervisor Maintenance planner Maintenance plannerTask listTask list Maintenance plan Maintenance plan ScheduleSchedule Technical completion Technical completion Create maintenance plansCreate maintenance plans Schedule maintenance plansSchedule maintenance plans Technically complete maintenance orders Technically complete maintenance orders55 22 33 11 Create task lists for different objects Create task lists for different objects Phase Contents Roles
- 64. Maintenance Activity Types PMactivity typesPM activity types - Inspection - Maintenance - Repair - Revision - Cleaning - Warranty - Insurance . . . - Inspection - Maintenance - Repair - Revision - Cleaning - Warranty - Insurance . . . - Function for grouping the actual costs in the object history - Function for grouping the actual costs in the object history PM order typesPM order types - PM01 - PM02 - PM01 - PM02
- 65.
- 66. Technical Permits Permit A001 Boilerusage permit A002 Welding permit A003 Safety check Assignment Technical object Order 10 Renew weld 20 Check electrics A002 Welding permit Create order >> Permit is copied A002 Welding permit 1 2 Permit A002 must be issued Release ? 3
- 67. Print Control Define shoppapers •Program Print proposal for each document type General / user-specific print specifications Selection
- 68. Printing Notifications andOrders Printing orders and notifications together Using the same forms Revising shop papers
- 69. Printing Orders Order 0010 0020 Shop paps.Description Output device 2010 2020 Op. Control ticket Job ticket A000 Print diversion 2030 2040 Select shop papers A000 A000 A000 Pick list Time ticket Change order Print directly X
- 70. Order history Equipment /Funct. location Operations Internal/external Material components Costs by valuation category Historical maintenance order Object list Equipment Equipment Functional loc. Completed Notifications Equipment / functional location Historical Maintenance Orders Data transferData transfer Direct entry Direct entry
- 71. Order execution Actual costs •Time confirmations • Material withdrawals • Goods receipts Costing Actual Costs for the Order Order 870986 Order 870986
- 72. Order 902263 Values inUS $ Cost elements Analyze Cost Results: Order Plan Actual Plan quantity Actual quantity 251.94 -* 650000 Order settlement ** Settlement 251.94 - *** Balance 511.56 * 400000 Consumption of raw materials 18.00 7.58 9 PC 3 PC * 403000 Use of operating supplies . . 45.00 45.00 1 PC 1 PC 488.56 199.36 5 H 2 H 511.56 251.94 X X * 615000 Direct internal activity . . ** Debit 251.94 - 2 H - 2 H - 2 H - X X 4100 Technical service Detailed Cost Analysis with CO Report
- 73. Plant Maintenance Controlling Order Planning Release Execution Completion confirmation Technical completion Settlement (Business) completion • Order notmodifiable • Postings can be made to the order • Postings cannot be made to order Time Options for Order Completion
- 74.
- 75.
- 76. Structure of MasterWarranty Warranty type Description Classification Warranty type Description Classification WarrantyWarranty headerheader WarrantyWarranty headerheader WarrantyWarranty itemsitems WarrantyWarranty itemsitems WarrantyWarranty countercounter WarrantyWarranty countercounter Service activities inclusive/exclusive Service activities inclusive/exclusive Counters, limitsCounters, limits
- 77. Important Transaction codes 01Functional Location Master IL01 02 Equipment Master IE01 03 Material Master MM01 04 Bill of Material (FL) IB11 05 Bill of Material (Equipment) IB01 06 Bill of Material (Mateerials) CS01 07 Work Center IR01
- 78. Important Transaction codes 08Material Where used List CS15 09 Task list IA01 10 Maintenance plan IP01 11 Maintenance Schedule IP10 12 Dead line Monitoring IP30 13 Catalog QS41 14 Measuring point IK01
- 79. Important Transaction codes 15Measuring Document IK11 16 PRT - Equipment IE25 17 Notification Creation IW21 18 Maintenance order Creation IW31 19 MTTR & MTBF for FL MCJC 20 MTTR & MTBF for Equipment MCJB
- 80. Thank you Contact Rupesh SAPPM Senior consultant + 91 866 08 169 19