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1. PM-
Plant
Maintenance
Module
SAP R/3

2. Organizational Structures in PM
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 Maintenance Planning
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 scenarios can 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 perform the 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. Work Center

8.  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.
 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. Functional Location

10. Functional Locations
The functional location 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 hierarchies Structure technical systems
based on
Criteria

12. Example of a FL 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
Hierarchy levelsHierarchy 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. Equipment

15. Equipment
Individual, physical object that 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
Functional location
Equipment

17. History of Document Changes
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 master record
Equipment BOM
Functional
location BOM
Equipment master
record
Functional location
master record
Material
Bill of Material Categories

21. Material Master

22. ROH - Raw Materials
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.Part no
2. Industry Sector
3. Material Type

24. Initial screen 2
1.Plant
2. Storage Location

25. Measuring Points and
Counters

26. PressurePressure
1010
2020
3030
4040
5050
6060
7070
8080
22 33 55 11
KilometersKilometers
TemperatureTemperature
00 11 22 77 55
Operating hrsOperating hrs
Measuring Points and Counters

27. Meas. Doc.
1010
2020
3030 4040 5050
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. PRT (Production Resource
Tools)

29. PRT (Production Resource
Tools)
To perform 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
Functional Locations 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 is a 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 - Maintenance request
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
and unit
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
.
.
.
Electrical work
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
Object part
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
• Maintenance order is also called work order
process which is the different maintenance
business process/flow carried by business.

39. Order Category, Order Type
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 in PM
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 not This 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 not This 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 not brThis 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 I organize 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 lot created
Calibration
Inspection
Result recording
Defects recording
Usage Decision
Calibration
History in
SAP
Notification
Calibration inspection

46. REFURBISHMENT PROCESS
a not Refurbishment 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. PREVENTIVE MAINTENANCE
Task List

48. Maintenance task lists describe 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 task listEquipment 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
Internal and 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. Maintenance Plan

52. Maintenance Plan: Functions
Cycle start 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
Maintenance plan
Single cycle plan Multiple counter plan1
Overview: Maintenance Plans

54. Responsibilities /
Planning data
Reference object
Task list
3 months
Interval (cycle)
Maintenance itemMaintenance item
Maintenance plan
Scheduling data
Maintenance item
Single Cycle Maintenance Plan

55. Maintenance Plan with Task 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
Cycle start
Start date
RestartRestart
New
Cycle start
Scheduling Functions - Single Cycle Plan

57. 15.03.2000 15.06.2000
= Planned dates
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 must be
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
Package number
Description
Cycle length
Unit of
measurement
Hierarchy
Offset
Preliminary /
follow-up buffer
Maintenance Package

61. 6 months
6 months
3 months
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 should be
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: Phases and 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
PM activity 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.  Technical permits
(unclassified)
Permits
Order
0010
0020

66. Technical Permits
Permit
A001 Boiler usage 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 shop papers
•Program
Print proposal
for each
document type
General / user-specific
print specifications
Selection

68. Printing Notifications and Orders
 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 in US $
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 not modifiable
• Postings can
be made to the
order
• Postings cannot
be made to order
Time
Options for Order Completion

74. Warranty Types
ManufacturerManufacturer
warrantywarranty
VendorVendor
warrantywarranty

75. Warranty

76. Structure of Master Warranty
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
01 Functional 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
08 Material 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
15 Measuring 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 SAP PM Senior consultant
+ 91 866 08 169 19