Predictive Maintenance Order

Predictive maintenance helps us to identify and carry out maintenance activities based on
the condition of equipments. This process is used to map the activities done by the fans, blowers
etc.

Creation of Measuring Point (IK01)

Measuring Points will be created to capture the readings for the various parameters
that indicate the Performance of a equipment.

Creation of Measurement Documents (IK11)

Readings for the various measuring points have to be entered by users regularly for
the proper working of plans. If these documents are not maintained properly the
system will create orders based on the daily usage data maintained in the Measuring
Point.

Create Notification (IW21)

In case the reading falls outside the acceptable range, the Notification type M3
would be automatically raised by the system to intimate the concerned department
about the problem. Probable guidelines for rectifications can also be mentioned as
texts in the Notification.

Create Maintenance Order(IW31)

Creation of Maintenance Order should be done by the Maintenance Department
through Order Type (PM03) Predictive Maintenance Order. If required a separate
plan can be created for generation of orders based on time schedules.

Select Operation and corresponding Control Key

Operations can be Internal or External. For internal operation, PM01 control key is to
be used and for External services, PM03 control key is to be used. The SOP can be
maintained in Tasklists, which can be attached to the order.

Allocation of Components in Maintenance Order

Here after selecting the Internal operation, the components that are required to perform
the maintenance activity are entered along with quantity and item category. This
automatically creates a Reservation

Allocating External Services in Maintenance Order

Here after selecting the External operation, the following details need to be entered:
Service Number/Short text
Quantity
Unit of measure (for non-standard services)
Gross price

View Planned costs

After allocating components and/or external services and saving the order, the plan
costs can be viewed

Release Maintenance order (IW32)

Maintenance order needs to be released before any component issue/ service entry
sheet can be created

Issue Components against reservation(MB1A)

Stores person will issue the reserved material against the order. However unplanned
items also may be issued to the order
Creation of PO (incase of External service)(ME21N)
PO is to be created for External services with reference to the Requisition number
generated in the Maintenance Order. This PO is to be handed over to the service
vendor.

Carry out Physical maintenance activity

This is the physical activity of carrying out the Maintenance job (Outside SAP)

Create Service Entry Sheet(ML81N)

Service entry sheet will be created after successful completion of the planned External
services. This will enable payment to be released for the Vendor.

Change / Complete Notification(IW22)

Notification will be closed after noting down all catalog & details of maintenance
required to be recorded as part of History.

Order Confirmation and Technical completion of the order(IW41/IW32)

During order confirmation, actual manpower, time etc. required to carry out the
particular maintenance activity are recorded. The Order is technically completed after
all operations planned in the order are completed. This indicates that the planned
maintenance is over.

Return of un-utilized spares to stores(MB1A)

The unutilized spares may be returned to stores against the maintenance order for
which they had been issued.

View Costs(IW32/IW33)
The Planned vs. actual costs can be viewed after all issues and service entry sheets
are completed.

Order settlementKO88/KO8G)
Settle the order. Order can be settled individually or collectively. The order settlement
ensures that the costs collected in the order are settled to the individual Cost
centres/AUC/Fixed Assets as defined in the Settlement rule. It is recommended that
settlement of completed orders are carried out on a weekly basis. To facilitate this
we will make entry of settlement rule mandatory at the time release of
orders.

Business Completion of order(IW32)

Business completion is not possible before order settlement & if the variance in cost is
not zero. Once Business completion is carried out for an order, it cannot be processed
further.
This can be carried out via menu path
Order>Functions>Complete>Complete Business.
Target Value 15mm/s

Lower Range Limit 10mm/s

Upper range limit 20mm/s

After creating measurement document with measurement reading 25mm/s

As the reading lies outside the range the system create notification of M3 type
Then we can create maintenance order(PM03) from notification & process the order same as any
other maintenance order type.

Then the create predictive maintenance order screen will open.

Select Operation and corresponding Control Key

For operation 0010 give control key PM01

Specify work as 4Hr, Number. as 2 and select calculate duration from Cckey

Then following screen will appear

Allocation of Components in Maintenance Order
In component tab give component as 1101900017 & quantity as 2 then press enter

Then a dialog box will open then specify the Good recipient as Engg. Store
Allocating External Services in Maintenance Order
In the operation tab for 20 operation give control key as Pm03 & operation short
text then press enter then following screen will appear

Specify material group 1741 for example

Purchase group as R02/Risra then press enter

Select that operation & click on general tab

Then the following screen will appear

Give the sevice number,Quantity & price

Then save the order.

View Planned costs

If u go the order in change mode & click on cost tab u will find the planned cost.

Release Maintenance order (IW32)

Maintenance order needs to be released before any component issue/ service entry
sheet can be created

Then release the order.Then the following screen will appear.

Issue Components against reservation(MB1A)

We have to issue the component against reservation.Select the component Click

on general data tab u will find the reservation number i.e 1997787

We have issue material against reservation.

Go to Mb1a

Give plant-rsr

M.type-261

Then click on To reservation give the reservation number then press enter
Then the following screen will appear

Then click on save.

Creation of PO (incase of External service)(ME21N)
We have to create PO with reference to the requisition

Po is released then service entry sheet is created.These activities are done by

the purchase people.

Order Confirmation and Technical completion of the order(IW41/IW32)

Then we confirm the order using IW41.
Then save the confirmation.

View Costs(IW32/IW33)
The Planned vs. actual costs can be viewed after all issues and service entry sheets
are completed
Order settlementKO88/KO8G)
Then settle the order using KO88
Business Completion of order(IW32)

Make the order as business complete.