5. Preventive Maintenance: Plan Types
Time-based
Maintenance plan
Single cycle plan Multiple counter planStrategy plan
Performance-based
Service Procurement
6. Building Blocks
1. When
Cycle or strategy that determines when a PM should
be done
2. Where – Equipment or Functional Location
The asset, assets, or location where the work is to
take place
3. What – Task List
Define tasks, materials and tools that are required
8. Maintenance Plans with single Asset
• You can create several maintenance plans.
• Each maintenance plan contains a maintenance item that describes the object to be
maintained.
• The system generates a separate order for each object on a due date.
10. Maintenance Plans with Asset list
• You create one maintenance plan.
• You assign an object list to the
maintenance plan in which all object
to be maintained are listed.
• The system generates an order for all
objects on a due date.
• Supports inspection routes,
lubrication routes
12. Leverage – LAM, OAA, GEO.e with Plan
Linear Assets can be
represented in plans
Use Geo.e to add spatial
data
Operational Account
Assignment provides cost
of inspection at the exact
position of the work
14. Inspection results support long term planning
Use results to feed
the long term
asset planning
Leverage PPM to
support the long
term plan
1
23
Create Inspection
plans
Gather results
Create long term
plan
4
Analyze results
15. Maintenance Plans with Strategy
• You create one maintenance plan.
• You assign an object list or a single
asset.
• The system generates an order for all
objects on the due dates with the tasks
that match the strategy.
• Supports a single plan with different
tasks per call date
• Can be performance or time
• The strategy unit must be consistent
16. Maintenance Plan with Notification
Made possible once multiple
Notifications could be added
To a single order.
Also possible to add task list
in a notification as of
ERP2005
18. Preventive maintenance – in most
organizations today
SAP ERP
Transformer
Work orders are
created in regular
Intervals
Technician is executing work
Work
order
19. Agenda
The Core – Preventive Maintenance
The Core – “Light” CBM
“and More”
25. Condition based maintenance (using mobility)
SAP ERP
Current
Temperature
Voltage
Transformer
SAP determines whether
Work order should be created
Technician is executing work
Technician feed rounds information
Into SAP to populate
measurement documents
Current
Temperature
Voltage
Transformer
Current
Temperature
Voltage
Transformer
26. Agenda
The Core – Preventive Maintenance
The Core – “Light” CBM
“and More”
27. Condition Based Maintenance The Goal
Easily accessible dashboards
allow asset managers and staff to
monitor asset health in real time
via measurement points
Real-time alerts via
dashboards give instant
updates on equipment status
and allow rapid reaction
Links to ERP data to trigger
maintenance workflow to
reduce unplanned downtime
and improve reliability.
Asset health
Continuous improvement
Best practice
Trend analysis identifies
problem areas for
immediate investigation
V.P.
28. • Quite a few of equipment delivered today have built in
sensors
• New sensors (temperature, leakage, etc.) are very affordable
• Collection, analysis and integration into SAP can be setup in a
few weeks
Current Situation
SAP ERP
Current
Temperature
Voltage
Transformer
29. • The historian collect lots of data but provides little
information to SAP
• Investments in the historian data has been made that is not
leveraged
• EAM groups does not have visibility to condition data in SAP
to make/optimize their decisions
Challenges
30. Integrated condition based maintenance
SAP ERP
Current
Temperature
Voltage
Transformer
Data
Historian
SAP MII
Determine whether
or not to create notification
or work order
Work order is made
available to the
Technician
Technician is executing work
OSI PI
APPs
Current
Temperature
Voltage
Transformer
Current
Temperature
Voltage
Transformer
31. Integration and Intelligence
Integration: A single layer enabling SAP ERP
connectivity into real-time systems to drive
equipment-to-enterprise business process
interoperability
Intelligence: Real-time analytics engine that
aggregates and delivers unified visualization of
events, alerts, KPIs and decision support to
personnel thru role-based dashboards
32. Rule Name (MII
Transaction)
Description
DailyRunHourUpda
te
This rule updates the run hours per equipment based
on a summarized, binary IsRunning Tag. Parametera are
the tag name and the Measurement Point name
NotificationOnExc
eedThreshold
This rule creates a notification once a tag value has
exceeded the Threshold value. The Threshold value can
be a tag or static value
… ….
Condition Based Maintenance - Detail
Tag Name
AB323DS
DS.32.1231
PUMP3223.TP
1. Select Asset
2. Select Rule
3. Associate Tags and/or fixed values
4. Select Frequency
5. Submit to database
Threshold Temp: 121
MII DB
33. Enter inspection data
• Provide maintenance staff with
a means to manually input
measurement readings
• Easy-to-use Web-based
interface allows untrained staff
to enter inspection results
• Easily delete or modify an
erroneous entry
Manual Entry of Inspection
Data
34. Asset Health Alerts
• Visual indicators and e-mail notifications alert maintenance staff to the assets in the most critical status
• Data-driven notifications alert users to changes in asset health status so that they can react
appropriately and make informed decisions quickly
• Maintenance staff can trigger a maintenance request if warranted
• Prioritized asset management enables a consolidated alert view
35. Asset Health History
• Communicate real-time asset health status, monitor and adjust maintenance plan
• Clear data layout and status indicators allow you to quickly compare current with target asset output.
• Aggregate health status
• Gauges visualize the criticality of current asset health
• Search by specific asset domain for monitoring
• Option:
• SAP 3D Visual Enterprise provides a 3D visual image of the asset being monitored
36. What’s in each solution?
Software
Quickly address the most urgent business
processes
Content
SAP-supported best practices, templates,
and tools make solution adoption easier
Enablement
Guides and educational material speed end-
user adoption
Service
Fixed scope and price provide maximum
predictability and lower risk
SAP Rapid
Deployment
solutions
37. Business challenges There is a solution
SAP Condition-Based Maintenance rapid-
deployment solution enables your organization to
perform maintenance only when necessary by
arming maintenance teams with sophisticated
intelligence and comprehensive asset health
dashboards. The solution also enables manual and
automatic triggering of maintenance workflow
leveraging through native integration with the SAP
Enterprise Asset Management (SAP EAM) solution.
Get started with condition-based
maintenance quickly and affordably
Critical asset failures which can have serious
environmental and enterprise level consequences as
demonstrated by recent high-profile industrial
catastrophes
Finding a CBM solution that has low entry, low TCO,
and leverages existing SAP investments
Traditional time or counter-based maintenance
strategies missing a dynamic component leading to
higher maintenance cost
Other RDS available is Asset Health Visualization
38. What does SAP deliver? What do you have to do?
Provide IT infrastructure (server)
Install SAP MII, version 12.2, on the development
and production environments
Install SAP BusinessObjects Dashboards software to
make optional changes to predefined health index
dashboards
Provide asset hierarchy structure from existing SAP
ECC and SAP EAM applications and information on
tag thresholds
Provide access to existing shop floor system with
connector from SAP Plant Connectivity
Provide appropriate contacts in the business and IT
departments
Conduct end-user training and change management
Conduct performance and integration testing
Perform data migration and cleansing
Transport to production
Key deliverables
Perform installation check
Lead workshop to confirm predefined requirements
Set up MII connectivity with shop floor system via
connector in SAP Plant Connectivity
Set up the plant database schema for storing shop
floor aggregate data
Configure the asset health index to meet customer-
specific dashboard requirements
Activate and test solution
Enable knowledge transfer to key users
Enable support for go-live
39. System requirements
SOFTWARE
• SAP ECC 6.0 EHP4 or above
• SAP Manufacturing Integration & Intelligence (SAP MII) on SAP NetWeaver® CE 7.3
version 12.2, SP4 or above
• SAP Plant Connectivity 2.2, SP3 or above
• SAP BusinessObjects Dashboards 4.0 SP4 or above*
• SAP 3D Visual Enterprise application (optional)
DATABASE
• SAP HANA® 1.0 SP5 or above (optional) **
* required only for customizing dashboards
** SAP HANA® content supporting cross-plant implementation is provided. However, the
standard service offering supports a single plant implementation.
40. In the system
• Link CBM monitoring system to
Historians to gather real-time data
• perform manual inspection and
then enter results into CBM
monitoring system
• Evaluate data to trigger automated
maintenance notification via CBM
rules and logic
• Perform maintenance jobs with
visual support using SAP 3D Visual
Enterprise
• Perform trend analysis by viewing
historical plant data
41. Conclusion - Benefits
– Minimize risks and stay in
compliance via alerts of imminent
catastrophic asset failures
– Manage investment risk by starting
with a baseline scope and then
scale it gradually
– Reduce maintenance due to fewer
reactive repairs of broken
equipment
– Support effort to stay within
regulatory compliance
– Reduce maintenance rework and
mean-time-to-repair (MTTR)
– Operate equipment in an
economically and environmentally
sustainable way
– Increased return on assets (ROA)
– Maximized asset utilization
– Improved overall equipment effectiveness (OEE)
– Reduced operational risk in asset management
– Reduced maintenance cost as a percentage of revenue
45. THANK YOU FOR PARTICIPATING
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SESSION CODE: 8595
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