SAP Plant Maintenance

Contents
Introduction .......................................................................................................... 9
Unit 1: Plant Maintenance Overview ............................................................... 11
Corrective Maintenance ................................................................................ 11
Basic Notification .................................................................................... 12
Work Order Process ............................................................................... 14
Basic Work Order Planning .................................................................... 17
Logistics Planning ................................................................................... 17
Execution Planning ................................................................................. 17
Basic Scheduling .................................................................................... 18
Preventive Maintenance ................................................................................ 19
Calendar-Based PM Plans ..................................................................... 20
Performance and Counter-Based PMs (Preventive Maintenance Work
Orders) .................................................................................................... 20
Summary ....................................................................................................... 21
Review of Terms ........................................................................................... 22
Demonstration and Exercise ......................................................................... 22
Create a Notification ............................................................................... 23
Create a Work Order .............................................................................. 27
Release a Notification and Work Order .................................................. 35
Confirm the Work Order .......................................................................... 39
Complete the Work Order ....................................................................... 41
Unit 2: Plant Maintenance and Reliability ...................................................... 43
Inspection vs. Monitoring............................................................................... 44
Preventive vs. Proactive ................................................................................ 45
SAP-PM and Regulatory Compliance ........................................................... 45
Plant Maintenance and Cost Tracking .......................................................... 46
Feeding Back Corrective Data into PM ......................................................... 47
Failure Data ............................................................................................ 47
Business Process Integration ........................................................................ 49
Maintenance Management Good Practice .................................................... 50
Unit 3: Plant Maintenance Asset Data ............................................................ 53
Functional Locations ..................................................................................... 53
Demonstration and Exercise................................................................... 58

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Basic Functional Location Configuration ................................................. 59

Define Functional Location Categories ................................................... 59
Define Functional Location Structure Indicator ....................................... 61
Define Field Selection for Functional Locations ...................................... 63
Demonstration and Exercise ................................................................... 65
Equipment ...................................................................................................... 66
Creation and Installation of Equipment ................................................... 66
Demonstration and Exercise ................................................................... 72
Basic Equipment Configuration ............................................................... 73
Maintain Equipment Category ................................................................. 73
Define Equipment Number Ranges ........................................................ 74
Define ABC Indicators ............................................................................. 76
Demonstration and Exercise ................................................................... 78
Define Field Selection for the Equipment Master Record ....................... 78
Assign User Status Profile to Equipment Category ................................ 79
Define History-Related fields ................................................................... 80
Additional Technical Objects ......................................................................... 82
Sub-Equipment........................................................................................ 82
BOMs (Bills of Material)........................................................................... 84
Demonstration and Exercise ................................................................... 87
PM Assemblies ........................................................................................ 88
Materials .................................................................................................. 90
Object Linking .......................................................................................... 91
Summary........................................................................................................ 91
Unit 4: Plant Maintenance Organizational Elements ..................................... 93
Plants ............................................................................................................. 94
Plant Dependencies ................................................................................ 94
Plant Maintenance Configuration Settings .............................................. 95
Maintenance Plants ................................................................................. 95
Planning Plants ....................................................................................... 95
Configuration of Plants ............................................................................ 95
Demonstration and Exercise ................................................................. 104
Work Centers ............................................................................................... 105
Configuration of Work Centers .............................................................. 106
Configuration of Work Centers .............................................................. 107
Define Work Center Types and Link to Task List Application ............... 108
Define Field Selection for Work Centers ............................................... 110

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Set Parameters for Work Centers......................................................... 110

Define Standard Value Keys for Work Centers .................................... 112
Define Employees Responsible for Work Centers ............................... 114
Define Default Capacity for Work Centers ............................................ 115
Define Default Work Centers ................................................................ 116
Configure Screen Sequence for Work Centers .................................... 122
Demonstration and Exercise................................................................. 125
Planner Groups ........................................................................................... 126
Maintenance Planner Groups ............................................................... 127
Capacity Planner Groups ...................................................................... 130
Demonstration and Exercise................................................................. 131
Unit Summary.............................................................................................. 131
Unit 5: Plant Maintenance Transactional Objects ....................................... 133
Notifications ................................................................................................. 134
Malfunction Reports and Maintenance Requests ................................. 134
Tasks .................................................................................................... 135
Catalogs ................................................................................................ 137
Status Management .............................................................................. 141
Configuration of Notifications ................................................................ 142
Define Notification Types ...................................................................... 143
Set Screen Templates for the Notification Type ................................... 144
Define Transaction Start Values ........................................................... 147
Assign Standard Texts for Short Messages to Notification Types ....... 148
Allowed Change of Notification Type .................................................... 149
Assign Notification Types to Order Types ............................................ 149
Demonstration and Exercise................................................................. 150
Creation and Maintenance of Code Catalogs ....................................... 151
Maintain Catalogs ................................................................................. 152
Define Catalog Profile ........................................................................... 154
Change Catalogs and Catalog Profile for Notification Type ................. 156
Demonstration and Exercise................................................................. 157
Notification Processing ......................................................................... 157
Define Priorities..................................................................................... 158
Define Response Time Monitoring ....................................................... 161
Define Status Profile ............................................................................. 162
Create Authorization Keys for User Status Authorizations ................... 165
Maintain Selection Profiles ................................................................... 165

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Define Object Information Keys ............................................................ 167

Assign Object Information Keys to Notification Types .......................... 169
Define System Conditions ..................................................................... 170
Define Operational Effects .................................................................... 171
Demonstration and Exercise ................................................................. 171
Work Orders................................................................................................. 172
Operations ............................................................................................. 178
Material Commitment and Procurement ............................................... 179
Labor Planning ...................................................................................... 180
Service Planning ................................................................................... 180
Standard Texts ...................................................................................... 181
Demonstration and Exercise ................................................................. 183
Production Resources and Tools .......................................................... 184
Configuration of Work Orders ............................................................... 186
Configure Order Types .......................................................................... 187
Indicate Order Types for Refurbishment Processing ............................ 190
Order Types and Investment Management .......................................... 190
Configure Number Ranges ................................................................... 191
Assign Order Types to Maintenance Plants .......................................... 192
Assign Inspection Types to Maintenance/Service Order Types ........... 193
Define Default Value for Planning Indicator for Each Order Type ........ 193
Create Default Value Profiles for External Procurement....................... 194
Define Access Sequence for Determining Address Data ..................... 195
Create Default Value Profiles for General Order Data .......................... 196
Default Values for Task List Data and Profile Assignments.................. 197
Settlement Rule: Define Time and Creation of Distribution Rule ......... 198
Define Proposed Reference Time for Technical Completion ................ 199
Define Transfer of Project or Investment Program ............................... 199
Define Relevant Fields for Assignment of IM Program ......................... 199
Define Default Order Types for Maintenance Items .............................. 200
Define Notification- and Order Integration............................................. 201
Demonstration and Exercise ................................................................. 202
Work Order Control Keys ...................................................................... 202
Maintain Control Keys ........................................................................... 203
Maintain Default Values for Control Keys for Order Types ................... 205
Maintenance Activity Types .................................................................. 206
Define Maintenance Activity Types ....................................................... 206

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Assign Valid Maintenance Activity Types to Maintenance Order Types207

Default Values for Maintenance Activity Type for Each Order Type .... 208
Costing Data for Maintenance- and Service Orders ............................. 209
Define Change Docs, Collective Purc. Req. Indicator, Operation No.
Interval .................................................................................................. 210
Set Workflow for Orders ....................................................................... 211
Define Documentation for Goods Movements for the Order ................ 212
Set List Editing for Goods Movements for Orders ................................ 212
Reorganization of List for Goods Movements for Orders ..................... 212
Define Checking Rules ......................................................................... 213
Define Scope of Check ......................................................................... 214
Define Inspection Control ..................................................................... 216
Assign Standard Texts for Short Messages to Order Types ................ 218
Define View Profiles .............................................................................. 219
Assign View Profiles to Order Types .................................................... 220
Demonstration and Exercise................................................................. 221
Maintenance and Work Orders: General Data .................................... 222
Define Default Values for Component Item Categories ....................... 222
Define Movement Types for Material Reservations.............................. 223
Define Account Assignment Cat. and Document Type for Purchase
Requisitions .......................................................................................... 223
Define Accounting Indicators ................................................................ 224
Define Priorities..................................................................................... 224
Create System Conditions or Operating Conditions ............................. 227
Activate Default Value for Current Date as Basic Date ........................ 228
Define Default Values for Units for Operation ...................................... 229
Define Status Profile ............................................................................. 230
Create Authorization Keys for User Status Authorizations ................... 233
Work Order Partner Determination: ...................................................... 233
Define Partner Determination Procedure and Partner Function ........... 233
Work Order Scheduling: ....................................................................... 237
Maintain Scheduling Types ................................................................... 237
External Scheduling .............................................................................. 240
Create Revisions .................................................................................. 240
Production Resource/Tool Assignments .............................................. 241
Define PRT Control Keys ...................................................................... 241
Formulas ............................................................................................... 242
Define Shop Papers, Forms, and Output Programs ............................. 243

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Define Printer ........................................................................................ 245

Message Control ................................................................................... 247
Assign Default Values for Settlement Areas to Order Types ................ 247
Define Object Information Keys ............................................................ 248
Assign Object Information Keys to Order Types ................................... 250
Interface for Procurement Using Catalogs (OCI) .................................. 251
Maintenance Event Builder ................................................................... 252
Maintain Revision Type ......................................................................... 252
Maintain Revision Number Range ........................................................ 253
Completion Confirmations ..................................................................... 254
Define Control Parameters for Completion Confirmations .................... 254
Define Causes for Variances ................................................................ 257
Define Execution Time for Confirmation Processes ............................. 258
Parallelized Confirmation Processes .................................................... 258
Schedule Background Jobs Confirmation Processes ........................... 259
Set Screen Templates for Completion Confirmation ............................. 259
Demonstration and Exercise ................................................................. 261
Summary...................................................................................................... 262
Unit 6: Preventive Maintenance Objects ........................................................ 263
Task Lists ..................................................................................................... 264
Task List Types ..................................................................................... 264
Maintenance Strategies and Package Assignments ............................. 265
Configurable General Task Lists ........................................................... 266
Configuration of Task Lists .................................................................... 266
Define Task List Usage Keys ................................................................ 267
Maintain Control Keys ........................................................................... 268
Define Suitabilities ................................................................................. 270
Maintain Task List Status ...................................................................... 271
Define Task List Usage ......................................................................... 272
Maintenance Task List Profile Data ...................................................... 273
Default Value BOM Usage for Free Material Allocation ........................ 274
User Fields ............................................................................................ 274
Demonstration and Exercise ................................................................. 276
Preventive Maintenance Items .................................................................... 277
Single Maintenance Items ..................................................................... 277
Multiple Maintenance Items .................................................................. 278
Object Lists ............................................................................................ 278

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Preventive Maintenance Plans .................................................................... 279

Single Cycle Plans ................................................................................ 280
Strategy Plans....................................................................................... 281
Multiple Counter Plans .......................................................................... 281
Maintenance Plan for Service Procurement ......................................... 281
Configuration of Maintenance Plans and Maintenance Items .............. 282
Set Maintenance Plan Categories ........................................................ 282
Define Sort Field for Maintenance Plan ................................................ 283
Measuring Points and Measurement Documents ....................................... 284
Measurement Point ............................................................................... 284
Measurement Documents ..................................................................... 284
Configuration of Measurement Points, Counters, and Measurement
Documents ............................................................................................ 285
Make System Settings for Measuring Points and Measurement
Documents ............................................................................................ 286
Define Measuring Point Categories ...................................................... 286
Demonstration and Exercise................................................................. 288
Unit 7: Cross Application Objects.................................................................. 291
Classification ............................................................................................... 292
Overview ............................................................................................... 292
Creating the Classification System ....................................................... 292
Using the Classification System ........................................................... 293
Configuring the Classification System .................................................. 294
Define Default Settings ......................................................................... 295
Define Characteristics Groups .............................................................. 296
Define Characteristic Statuses ............................................................. 297
Define Template Characters ................................................................. 298
Define Templates .................................................................................. 299
Demonstration and Exercise................................................................. 300
Classes ................................................................................................. 301
Maintain Object Keys ............................................................................ 301
Maintain Object Types and Class Types .............................................. 303
Define Class Groups ............................................................................. 304
Maintain User Profile ............................................................................ 306
Demonstration and Exercise................................................................. 307
Save the class.Document Management ..................................................... 311
Document Management .............................................................................. 312
SAP Archive Link .................................................................................. 313

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Document Management for Technical Objects ..................................... 314

Object Services ..................................................................................... 315
Demonstration and Exercise ................................................................. 317
Summary...................................................................................................... 318
Unit 8: Integration of Plant Maintenance With Other Modules .................... 319
Finance ........................................................................................................ 320
Cost Centers ......................................................................................... 320
Cost Elements ....................................................................................... 320
Labor Activity Types .............................................................................. 321
Procurement ................................................................................................ 323
Material Masters .................................................................................... 323
Purchase Requisitions........................................................................... 325
Purchase Orders ................................................................................... 327
Outline Agreements and Contracts ....................................................... 328
Service Entry Sheets ............................................................................. 330
Demonstration and Exercise ................................................................. 332
Summary...................................................................................................... 333
Unit 9: Reporting .............................................................................................. 335
Overview of Reporting in SAP-PM............................................................... 336
Reporting on the Maintenance Work ........................................................... 337
Taking Control of the Maintenance Work .............................................. 337
Work Backlog Trend .............................................................................. 338
Preventive Maintenance Overdue Hours .............................................. 340
Preventive Maintenance Compliance .................................................... 341
Preventive Maintenance to Total Work Ratio ........................................ 341
Reactive Maintenance Ratio ................................................................. 343
Reporting on the Equipment ........................................................................ 345
Taking Control of the Equipment........................................................... 345
Bad Actor Report ................................................................................... 345
Breakdown Report ................................................................................. 348
Production Critical Equipment Availability ............................................. 350
Mean Time between Repairs (MTBR)................................................... 350
The Mean Time between Failures (MTBF) ........................................... 350
Demonstration and Exercise ................................................................. 352
Summary...................................................................................................... 358

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