Plant maint

breaking through barriers to 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

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
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
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
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
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
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
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
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
Maintenance Work Centers
SAP AG 1999
Maintenance work centers
For example:
Welding
Metalworking
Mechanics

11
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
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
Functional location = multi-level, hierarchical structure,
SAP AG 1999
Spatial
Technical
Functional
organized according to ...
Criteria
Functional Location

14
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
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
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
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
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
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
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
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
Maintenance Order: Putting in Process
SAP AG 1999
Status
'RELEASED'
Order papers
Put in process

23
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
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
Cycle for Corrective Maintenance
1
2
3
SAP AG 1999
Notification
Planning
Scheduling
Execution
Completion
• Description
History
• Date
• Malfunction
• Material
• Tools
• Order release
• Printout
4
5

26
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
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
Maintenance Notification: Object Information
SAP AG 1999
Maintenance dates Notifications
ii
Processing days
Object information
Documents
Links
Breakdowns
Structure list
Orders

29
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
Print Maintenance Notifications
SAP AG 1999
Maintenance
notification
Notification
overview
Breakdown
report
Activity
report
Fax transfer

31
1
3
SAP AG 1999
Notification
Scheduling
Execution
Completion
• Description
• Order release
• Printout
History
• Date
• Malfunction
4
5
PPllaannnniinngg • Work to be performed
• Material
• Tools
2

32
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
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
Stock Material - Process Flow
Component
assignment
SAP AG 1999
Material
reservation
May
Availability
check
Goods
issue
Printing
Order
release
Automatic
availability
check May

35
1
2
SAP AG 1999
Notification
Planning
Execution
Completion
• Description
• Date
• Malfunction
History
• Material
• Tools
4
5
SScchheedduulliinngg • Capacity leveling
• Order release
• Printout
33

36
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
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
Order Completion Confirmation: Times / Activities
SAP AG 1999
Times
Individual entry
Collective entry
Time sheet (CATS)
Activities
Activity reports
Confirmation texts
Object changes
Measurement readings

39
•Questions ??
•Contact Details :
mail id : gthangavelu@darylflood.com
Cell : 469-879-4674
Residence : 972-444-8510

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