SAP Plant Maintenance

Brief Background of
Presenter
Subhra works as SAP Systems Analyst at Iluka Resources

Limited, Perth, Western Australia

He has a Net experience of around 7.8 years with around 6

years of SAP Consulting Experience in SAP PM & CS, MM

modules. He has also has standard configuration
knowledge of SAP PS, DMS and integration aspects of other
SAP modules & applications
He has worked in multiple SAP Implementation, Upgrade,

Support & Audit assignments in Australia, USA, India and

Middle East and is an ex-employee of PwC India Ltd, T.C.S.
Limited
He also possesses Core Industry experience of 1.8 years in

Maintenance & Inbound Logistics

ERP Systems: An Overview

Plant Maintenance: An Overview
Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports

Governm
ent &
Authoriti
es

Vendors

Organizat
ion

Environm
ent

Customer
s

Vendors

Organizational ERP
SystemFinance
&
Controlli
ng
Purchasi
ng

HR &
Payroll

Government
&
Authorities

External
Environmen
t

Projects
Producti
on
Planning

Mainten
ance

Sales &
Distributi
on
Customers

ERP Systems: An Overview

Plant Maintenance: An Overview
Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports

 Maintenance is a Support Function within an Organization and

Maintenance costs generally constitute a part of Production overhead
costs except when Maintenance is carried out on Customer Assets to
earn revenue.
Primary Objective of Maintenance is to maintain a high level of
Availability, preventing degeneration and maintaining optimal
utilization life of an Organizations Physical Assets.
Physical Assets primarily comprise:
Fixed assets such as Plant & Machinery, Buildings & Properties,
Vehicles and so on. Usually such assets have a Long useful life (usually
> 1 year) over which they are depreciated
Operating Assets which may not be treated as Assets in Financial
Module nor depreciated, but having a long term utilization
High valued current assets such as High valued spares/operating
supplies/machine parts which are subject to Refurbishments with their
condition based values maintained accurately
Key Performance objectives in Maintenance include
Maintaining a high level of OEE (Overall Equipment Effectiveness)
Maintaining and Optimal balance between Cost of Breakdown vs.
Cost of Prevention
Utilizing concepts such as TPM, RCM etc. to contribute in Lowering

ERP Systems: An Overview

Plant Maintenance: An Overview
Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports

Centralized
Planning

Company
Code

Maintenan
ce
Planning
Plant
Maintenan
ce Plant

Maintenan
ce Plant

De-centralized
Planning

Maintenan
ce
Planning
Plant
Maintenan
ce Plant

ERP Systems: An Overview

Plant Maintenance: An Overview
Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports

Techni
cal
Object
s

Work
Centre
s

SAP
PM:
Maste
r Data

Others

Planni
ng
Object
s

Work
Centre
Hierarc
hy
Capac
ity

Capacity
informatio
n includes:

Unit of
capacity
Start/End
times
Utilizations
Shift
schedules
etc.

Work Centre Hierarchy is a

Grouping of Work centres
comprising Maintenance
Task Force

Work
Centr
e

PM Work
Centre
Category
0005
Comprises:
Basic data,
Default
values,
Capacity
view,
Scheduling
view, HR
Assignments,
Costing view

Sample
SAP
screenshot

Capacit
y
Plannin
g

Load
Monitori
ng
Capacit
y
Levelin
g

Capacity
Functionalities

Structured into
Hierarchical Levels using
Structure Indicators
Serial
Number

Material
No

Sample
SAP

Top Down
planning

Pla
n
Task List

Maintenance item

Bottom up
planning

 Single cycle Plans

Strategy Based Plans
Plans Counter Based Plans (Single/Multi
Counter)
General Task Lists
Task Functional Location Task Lists
Lists Equipment Task Lists
Standard items
Items Strategy based items

Other Master
Data

Class/
Characteris
tics

Permits

ERP Systems: An Overview

Plant Maintenance: An Overview
Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports