PM MODULE FOR EBG -POWAI PLANT

TEAM LEADER

: J S PATIL

TEAM MEMBERS

: : : :

M M KUNTE K A SARPOTDAR T M RAJAGOPALAN RAVI MORE

SBU 2 SBU 1 / SBU C SBU 3 PTL

TEAM STARTED WORKING FROM 01/12/2000 WILL GO LIVE IN 1ST WEEK OF APRIL 2001

SAP Plant Maintenance

SD
Sales & Distribution

FI
Financial Accounting

MM PP
Materials Mgmt.
Production Planning

CO
Controlling

AM

PM
Plant Maintenance
HR

Fixed Assets Mgmt.

QM
Quality Management

PS WF
Project System

Human Resources

Workflow

SAP Plant Maintenance

Major sub-functions:
Equipment and spares tracking Maintenance work management Preventive maintenance planning Maintenance information analysis (PM-IS) Measurements

SAP Plant Maintenance

Equipment and spares tracking
Functional Location (P&ID) data Equipment data Bills of Material Permits Equipment Tasklists (Standard jobs) Functional/Location Tasklists General Tasklists

Contents of a Functional Location

Functional location master record

Location data PM data

Multilingual texts
Equipment usage Classification Documents

Contents of an Equipment Master Record

Equipment master record
General data Location data PM data

Multilingual texts Internal note

Equipment usage
Classification Documents

SAP Plant Maintenance

Maintenance Work Management
creation of maintenance orders planning scheduling release confirmation settlement completion

Process Flow in PM
PM Organization
Plants PM Planner Work Centers (Workshops) Capacities Direct order creation PM Planning (Maintenance and inspection releases) PM Reqts./ Notifications (Malfunction reports)

PM Orders

Resources
Material

PM Objects
Functional Locations Equipment Assemblies

Internal Services

External Services

Completion Information

PM History Downtimes Costs ....

SAP Plant Maintenance

Types of Maintenance Orders
Preventive maintenance orders released by PM schedules at due dates Planned orders arising from maintenance notifications (malfunctions and work requests) Unplanned orders created if immediate action is required Standing (blanket) work orders

Basic Steps in Maintenance Processing

Plant Malfunction, error Request Activity
1 2 Requesting a maintenance Task 3

PM Planning
4
Order

PM Workshop
5

PM Notification what when where techn. information breakdown

Creating the order Planning the task who when, for how long what steps account assignment resources
7

Execution material issue procuring PRTs work steps

Techn. information breakdown causes objects affected activities

8
Completion

6
Completion confirmation

Completion

PM History

SAP Plant Maintenance

Preventive Maintenance Planning
Time based maintenance strategies Performance based strategies Counter based strategies Maintenance Tasklists (Standard jobs) Maintenance Plans Maintenance Order Scheduling

Maintenance Task List Structure

Task list header
Strategy, maintenance planning group, work center, equipment Work center, description, time, control key, external processing data, maintenance packages Operation, time, work center, description, control key Quantity, BOM item, item category, quantity unit

Operation Sub-operation

Material Maintenance resources

Maintenance packages

Quantity, category

Allocation of maintenance packages

Elements in Maintenance Planning

Maintenance Strategy Maintenance Plan Maintenance Order

MAINTENANCE STRATEGY MAINTENANCE PACKAGES: -Time based -Performance based - Counter based

MAINTENANCE SCHEDULE

SCHEDULED CALLS

MAINTENANCE ITEMS

MAINTENANCE ORDERS

-FUNCT LOCATIONS -EQUIPMENT -ASSEMBLIES

ACTIVITIES: -Equipment Tasklists -Function Loc. Tasklists -General Tasklists

SAP Plant Maintenance

Maintenance information analysis
Equipment breakdown Maintenance cost Like equipment analysis MTBF

SAP Plant Maintenance - Benefits

Provides up to date cost figures for better

maintenance decision making Realtime information flows between PM and other systems No software interfaces between plant maintenance (PM) system and other systems such as human resources, purchasing, payables, and payroll etc. Eliminates the need to pull data from difference systems for reporting purposes Lower software maintenance cost Lower software implementation cost

SAP Plant Maintenance

Maintenance orders detailed description
technical objects operations and sub-operations internal resources material list external resources schedule dates order header

Definition of a Maintenance Notification

for describing the condition of a maintenance object and the malfunction in particular
Malfunction report

for describing a maintenance activity that has already been performed - purely technical documentation Activity report

for requesting a maintenance activity/task

Maintenance request

Structure of a Maintenance Notification

Notification date/time/reported by description PM object: functional location equipment assembly location data account assignment data breakdown/availability data damage location damage cause of damage

Notification items

Activities

activity performed by

Maintenance tasks

dates task description

PM Overview Diagram

Master Data Pre-defined work steps Notifications Create Work Orders Emergencies Labor Special Tools Preventive/Predictive Maint. WOs Shop Papers Planned Work Orders External Services

Parts/Supplies

Material Requisitions

Reporting

Schedule WOs

Close and Settle WO

PM Master Data

Cost Equipment People

Vendor

Parts

Notifications Maintenance Orders

Plants Special Tools Repair Steps

Supplies

Factory Calendar

Locations

Planning & Scheduling

Notifications

Material Availability

Stock Reservations
Purchase Requisitions

Requisition to Purch. Order

Create Maint. Orders

Planned Maintenance Order

Release the Maint. Order

Schedule the Maint. Order 1. Manual 2. Automatic

Emergency Demand

Special Tools

Special Instructions

PP/ PM

Capacity Demand (Labor)

Delivery Schedule of Material/Services

Safety Considerations Material Reservations

Maintenance Order Functions

Capacity planning Operations Work centers Object list Objects Materials BOM Task list Costs External processing

Planning

Shop papers Material issue

Execution

Purchase orders Goods receipt Invoice receipt Completion confirmation

Cost center
Asset

Settlement

Project Order