SAP Plant Maintenance Module: Presented by Sourabh Sharma

SAP
Plant Maintenance Module

Overview
Presented by Sourabh Sharma
Copyright © 2004 Accenture All Rights Reserved.
Accenture, its logo, and High Performance Delivered are trademarks of Accenture.
Agenda
1. Introduction about PM
2. Structure of Organization with a view to PM

 Functional Location
 Equipment
 BOMs
3. Type of maintenance
Corrective maintenance
Master data in corrective maintenance
Corrective maintenance process
Preventive maintenance
Master data in preventive maintenance
Preventive maintenance process
Refurbishment
Refurbishment process
2 | 21 Oct, 2004 | oSAP Program

Copyright © 2004
2010Accenture
AccentureAllAll Rights
Rights Reserved.
Reserved. 2
Introduction to Plant Maintenance
 What?
Planning, processing and documenting of repair tasks for

corporate operation and production resources.
 Why?
To maintain the various resources of plants in order to ensure the

smooth and efficient working.
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 3
Activities under Plant Maintenance :
• Inspection
– All measures which establish the actual condition of a technical system
• Preventive maintenance
– All measures which maintain the ideal condition of a technical system
• Repair / Breakdown Maintenance

– All measures which restore the ideal condition of a technical system
• Maintenance Projects
– All Measures required to make modifications or add to existing
technical system
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 4
Planning Organization Structuring
• Centralized Maintenance Planning

– The company has several maintenance plants, however, only one plant
in which maintenance planning is performed.
• Decentralized Maintenance Planning

– The company comprises several maintenance plants. Each plant
performs its own maintenance planning.
• Partially Centralized Maintenance Planning

– The company comprises several maintenance plants. Some of the
maintenance plants perform their own maintenance planning, others do
centrally.
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 5
Structuring
• Maintenance Plant
– The maintenance plant for a technical object is the plant at which it is
installed
– E.g. Clarification plant C1 is located in plant 0001. Plant 0001 is
therefore the maintenance plant for the clarification plant C1.
• Maintenance Planning Plant

– The maintenance planning plant for a technical object is the plant in
which the maintenance tasks for the object are planned and prepared .
– E.g. The maintenance plant for the clarification plant C1 is plant 0001.
Plant 0001 does not perform its own maintenance planning. It is
assigned to plant 0002 . The maintenance planning plant for the
clarification plant C1 is therefore plant 0002.
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 6
Master data objects
Plant specific master data objects:

Work center
Functional location
Equipment
Assembly
Bill of material
Document and links
Object network
Global master data objects:

Material master
Classification classes and characteristics
Catalogues
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 7
Technical Objects
= Functional location
= Equipment
= Bill of materials
= Material

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 8
Functional location
Is a multi-level hierarchical breakdown structure

of machinery. Individual equipments can be
installed within this hierarchy.
Provides a context for executing and recording

maintenance tasks.
Provides a framework to monitor and track costs.
Provides a framework to monitor and track

location of equipments.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 9
Equipment
• Equipment is a uniquely identifiable physical

machine, upon which work can be carried out and
about which costs and history can be recorded.
• More than one piece of equipment can be installed
at a functional location.
Equipment should be created if:

• Individual data is to be managed for the object (for example, year of
construction, warranty period, usage sites).
• A record of the maintenance tasks performed for the object must be kept (e.g.
for insurance or legal inspection purposes).
• Technical data on the object is to be collected and evaluated over a long
period of time.
• The costs of maintenance tasks are to be monitored for the object.
• Records of usage times at functional locations are required for the object.
• Documents and BOM follow an equipment irrespective of installation location.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 10
Movements of an equipment
Functional Location
Functional Location Functional Location
Equipment Equipment Equipment

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 11
Equipment vs. functional location
Technical object Functional location Equipment
This is relatively stable, This is laid into a certain

may not be changed in position and it can be
years changed more often
Example Turbine Motor
Oil pump
Shaft

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 12
Equipment design
If the object at a functional location will never move physically, such

as a storage tank, it is not necessary to set up an equipment
record. Any work can be raised against the related functional
location.
Determine movable and non-movable machines to see whether
an equipment needs to be created or not.
Equipment can be installed on or dismantled from either a superior

equipment or a functional location.
Equipment needs to be installed on the correct functional
location during conversion.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 13
Bill of material
A maintenance Bill Of Material (BOM) is a structured list of the components

(i.e. functional location or equipment) or an assembly (material).
The BOM contains object numbers of individual components together with

their quantity and unit of measure. The components can be Stock or
Non-Stock Spares or Assemblies, which in turn can be described using
maintenance BOM’s.
Specifies only maintenance relevant components.
Maintenance BOM’s are primarily used for the following purposes:
Structure description
A maintenance BOM describes the structure of a technical object or material.
Using maintenance BOM you can specify exactly where maintenance tasks
are to be performed on a Technical Object.
Assignment of spare parts

A maintenance BOM is used in PM to assign spares for a technical object for
documenting and choosing materials.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 14
Bill of material structure
Equipment
BOM Header Functional
Location
Text Data
Quantity Data
Material
Administrative Data
General Data
BOM Item
• Item Category
• Item Status
• Purchasing Data
Sub-Item

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 15
Bill of material design
Use of generic BOMs (i.e. Material BOMs) rather then specific

functional location or equipment BOMs.
Material BOM - A generic BOM is applicable to one or many
equipments or functional locations. By using generic material
BOMs, maintenance is simpler since there are less BOMs.
Spare Parts will be in SAP as part of the BOM.

Material need to be defined before the BOM can be built.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 16
Document and links
Offers document references and an easy access to related

documents for
functional locations,
equipments and
machine models (materials).
Access within master data, notifications and work orders.
Requires organized servers and folder structures

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 17
Material master
Maintenance relevant materials are for example:

spare parts
assemblies
common machines
All data of a material is integrated in one master record.
Integration also enables the master data to be used jointly by

purchasing and other areas like inventory management and
invoice verification.
In maintenance processing materials are used e.g. in ordering and

reserving spare parts.
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 18
Classification classes and characteristics
Description Example Method
An attribute Pump capacity, 1. Create

Characteristics describing an object Pressure characteristics
A group of objects
Pumps, Electric
Class that has the same or
motors
2. Create a class
similar properties
Equipment, 3. Link the class to an

Object A classifiable unit
Functional location object
Pump capacity: 2000

Characteristics Acceptable values of 4. Assign values for
l/s, Pressure: 1,6
value a characteristic characteristics
MPa

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 19
Catalogues
Maintenance catalogues are groups of standardized codes used to report

technical history for work that has been performed.
There are various types of catalogues that can be defined in SAP. Typical
ones are:
Object part catalogue allow the user to specify the specific part of a piece of
equipment or functional location that work is being requested or performed
for.
Fault code catalogue allow the user to specify the type of damage that has been
observed.
Cause code catalogue allow the user to specify the root cause.
Activity code catalogue allow the user to specify what activities were carried out
to fulfill a work request or to document work that was carried out.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 20
Catalogues
Technical history associated with the repair and maintenance of

specified equipment provides a basis for monitoring plant and
equipment integrity, such as:
Frequency of failure
Failure grouping and analysis
Impacts of maintenance strategies (planned Maintenance, corrective
maintenance, run to failure)
Component reliability analysis
Support to report analysis
Standardized codes enable benchmarking.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 21
Catalogue structure
Catalogues for:
Object Part
part Causes Task
Damage
Malfunction Activities
Action
Catalogue Structure: Example :
Malfunction
Catalogue Catalogue
Code- Mechanical
Code Group Malfunction
group
Code
Code
Code 010 Corrosion
020 Broken Glass
030 Defect Engine
.. ..
. .

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 22
Corrective Maintenance
Corrective Maintenance
process process
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 23
Corrective maintenance process

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 24
Description of the process
The corrective maintenance planning process

Starts with creation of notification,
either a fault report
or a maintenance request,
ends with the creation of a maintenance work order,
includes several decision points whether to
create maintenance work order,
postpone to later or
cancel request.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 25
Notification life cycle
Postpone/
Notification Notification Assign to Complete
cancel/ Put in process
creation review order notification
continue
Notification Notification When When Once the After the

is created to in the notifications decision notification completion
report a fault system can are has been is put in of the
or request be reviewed reviewed, a made to process it notification,
for and decision is continue can be it is no
maintenance updated made with the assign to a longer
whether to notification, work order possible to
continue it will be put change /
with the in process. update it.
notification
immediately,
to postpone
it until later
or to cancel
it

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 26
Standard Maintenance Cycle – Data objects
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 27
Maintenance Order
• What is a Maintenance Order ?
It is a detailed planning of the maintenance task which has to be

performed.
• Why Maintenance Order ?

– Plan tasks in detail with regard to type, scope, dates and resources.
– Monitor the execution of tasks.
– Define rules for account assignment, settlement and budgets.
– Enter, assign and settle the costs which arise from tasks.
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 28
Information from the Maint. Order
• Location or Equipment needing the repair ( inherited from the

Notification data).
• List of activities to be performed and estimated completion times.
• Maintenance resource(s) to perform the activities.
• Spares required for the repair.
• Cost of the repair jobs carried – Planned & Actual.
• Where the costs of the order would be settled.
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 29
Maintenance Order Structure
Elements of Maintenance Order
For example: Order Type, Dates,Plant, Main object,

Order header Priority, Description, Maintenance Activity type
For example:- Functional Locations, Equipment

Object list Maintenance Notifications, Assemblies.
For example: Work Centre, Control key, Descriptions

Operation Standard time, Activity type,
Material list For example: Material, Quantity, Storage Location
Production resources/tools
Settlement Rule
Costs
(Estimated / Planned / Actual)
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 30
Maintenance Order in SAP
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 31
Notification vs. PM work order
Notification Work order

Technical object Object list
Classes Operations
damage work center
cause material
Activity history quantity
No costs resources
Settlement rules
Costs
estimated
planned
actual

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 32
Work order planning and scheduling

Starts after the maintenance work order has been created and finishes
when the work order is scheduled to execution.
The process includes planning of material
stock material from the warehouse
non-stocked material to be purchased for the order
and planning of resources
own resources
external services to be purchased.
The scheduling part co-ordinates timing of work orders.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 33
PM work order system status
System status
Automatically created
Shows actions taken or not taken
The work order can have several system statuses
Ex:
CRTD, order created
MANC, material availability not checked
PRC, precosted
PRT, work order printed
REL, work order released
PCNF, work order partially confirmed
TECO, work order technically completed.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 34
External services
External services will be processed in two different ways:

Frequently used contractor with a long time contract
Processed using an internal work order with an external work center.
Sporadically used contractor
Processed using purchase requisition and material master.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 35
Stock material process flow
Component
assignment
Availability Material
check reservation
Order
release
Printing
Automatic
availability
check Goods issue

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 36
Non-stock material process flow
Component
assignment
Purchase
application
Purchase
order
Goods receipt
Invoice receipt

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 37
PM work order release
Effects of order release:
Reservation effective, can be

withdrawn
Papers can be printed
Confirmation possible
Goods movement possible

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 38
Work order execution

Starts when the work order has been released for execution,
ends when the work has been completed and the costs are settled,
includes
material issue,
execution of the work,
time reporting,
updating notification,
updating technical object and
cost settlement.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 39
Technical order confirmation
Before the work order can be completed:
Time must be
confirmed
Activity reports
completed
Goods movement
reported
0013456998
Measurement
readings recorded

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 40
Technical completion
Effects of technical completion:
Limited ability to change order

Create settlement rule
Deletion flag for purchase requisitions
Close open reservations
Close open capacities

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 41
Reverse Technical completion
Effects of reverse technical completion:
Order becomes modifiable again

Status REL is set
Locations and account assignment
data are recopied from the object
Open purchase requisitions are
recompiled
Open reservations are recompiled
Open capacities are recompiled

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 42
Order cost
Planned cost are

calculated at order
planning
Estimated costs
are entered at
order creation Actual costs are
calculated at material
issue and time
confirmation
All costs can be viewed on work order

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 43
Preventive Maintenance
Preventive Maintenance
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 44
Master Data in Preventive
Master Data in Preventive
Maintenance
Maintenance
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 45
Master data objects
Plant specific master data objects:

Task list
Maintenance item
Measuring point
Global master data objects:

Maintenance strategy
Maintenance plan

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 46
What is a task list
Describes a sequence of individual operations which have to be completed
Related to a functional location and equipment
Types of task list

General task lists are maintenance tasks lists - sequence of tasks defined and managed
centrally and used for scheduling work on multiple equipments/sites
Object specific task lists are specific to functional locations or equipment
TASK LIST
……………………
STEPS …………………… LABOUR
……………………
……………………
……………………
……………………
……………………
EQUIPMENT ………………… MATERIALS

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 47
Maintenance task list structure
Task
Tasklist
list e.g. strategy, Task List
e.g. strategies, planner
maintenance planner
header group, main work center
group, work center, equipment
header
e.g.center,
e.g. work work center, description,
description, timing,time
Operation
Operation control key,external
externalservice
processing data,
control key e.g.
maintenance packages
e.g. operation, time, work center,

Sub-operation
Sub-operation description, control key
e.g. Material Numbers

e.g. quantities, quantities,
BOM items, BOM items,
Material
Material unit of measure
item category, unit of measure
Production
Production e.g.e.g.
Mobile Crane
amount, type
resources/tools
resources/tools
Maintenance
Maintenance e.g. Frequency
package
package

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 48
Preventive maintenance strategy
A maintenance strategy is a set of defined frequencies or packages

with scheduling parameters assigned to them
Time based maintenance strategy samples:

Weekly
Monthly
3 Monthly
Yearly
Counter based maintenance strategy samples:

Hours run
Liquid pumped out

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 49
Preventive maintenance plan
PLAN:
Started on date Some parametres Frequency set 1m 3m 6m 1a 3a
"Maintenance strategy" A
ITEM 1
WO Header info Tasklist: A
check x
calibrate x
tune x
replace valve x
ITEM 2
WO Header info Tasklist
lubricate x
balance x

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 50
Measuring point
Are used to enter measurements and counter readings (quantitative

operating data) for technical objects.
Measuring point is a physical and/or conceptual location at which a

condition is described.
Accumulated totals can trigger a PM Notification or PM Order.
Typical situations of use are:

Counter-based maintenance (preventive maintenance every 1000
production hours).
Condition-based maintenance (preventive maintenance when brake
pad minimum thickness has been reached).
Condition of the object is needed to be documented at a particular point
of time (e.g. legal, health and safety reasons).
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 51
Measuring point
Measurements and counter readings are represented in SAP as

measurement documents.
Measurement and counter reading data can be entered into SAP

e.g.:
Manually using SAP user interface.
Manually using browser and transferring it to SAP via Internet.
Semi-automatically using barcode reader and transferring it from
external system to SAP via interface.
Automatically transferring it from external system to SAP via interface.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 52
Preventive Maintenance Process
Preventive Maintenance process
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 53
Normal PM preventive maintenance process

Starts with the creation of a maintenance strategy.
Ends with automatic generation of work orders.
Includes maintenance task lists, plan creation and maintenance plan
scheduling.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 54
Preventive maintenance planning framework
1M * 1000 H
Strategy Package 2M * 8000 H
3M * 10000 H
etc.
Counter * Maintenance Plan
Object List Maintenance Item Call Object /Work Order
Task List
Sub Operation Operation
Material Master Vendor /Contract
Standard Text Service Master

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 55
Refurbishment Process
Refurbishment process
Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 56
Refurbishment
The refurbishment process starts with creation of a refurbishment work
order for a material number and
ends with completion of the work order.
Planning and scheduling of the refurbishment work order follows the
normal planning and scheduling process flow.
After the refurbishment work has been executed the refurbished
material may be put to stock.
For refurbished equipment the status is changed.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 57
Additional details
Refurbishment cases can be handled in different ways:

Equipment with normal PM work order, where equipment does not
have SAP serial number. These are major machines.
Smaller machines and major components with refurbishment work
order. These have normal material number with split valuation and
possibly a serial number.
Smaller low value components with standing work order and zero stock
value.
Before the equipment is refurbished, its status will be changed to

waiting to be refurbished.

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 58
Questions?

Copyright © 2004
2010Accenture
Rights Reserved.
Reserved. 59
Any Questions?
Thank you

SAP Plant Maintenance Module: Presented by Sourabh Sharma

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

SAP Plant Maintenance Module: Presented by Sourabh Sharma

Загружено:

Авторское право:

Доступные форматы

SAP

Plant Maintenance Module

2. Structure of Organization with a view to PM

2 | 21 Oct, 2004 | oSAP Program

Planning, processing and documenting of repair tasks for

To maintain the various resources of plants in order to ensure the

• Repair / Breakdown Maintenance

• Centralized Maintenance Planning

• Decentralized Maintenance Planning

• Partially Centralized Maintenance Planning

• Maintenance Planning Plant

Plant specific master data objects:

Global master data objects:

8 | 21 Oct, 2004 | oSAP Program

Is a multi-level hierarchical breakdown structure

Provides a context for executing and recording

Provides a framework to monitor and track costs.

Provides a framework to monitor and track

9 | 21 Oct, 2004 | oSAP Program

• Equipment is a uniquely identifiable physical

Equipment should be created if:

10 | 21 Oct, 2004 | oSAP Program

Functional Location Functional Location

Equipment Equipment Equipment

11 | 21 Oct, 2004 | oSAP Program

Technical object Functional location Equipment

This is relatively stable, This is laid into a certain

Example Turbine Motor

12 | 21 Oct, 2004 | oSAP Program

If the object at a functional location will never move physically, such

Equipment can be installed on or dismantled from either a superior

13 | 21 Oct, 2004 | oSAP Program

A maintenance Bill Of Material (BOM) is a structured list of the components

The BOM contains object numbers of individual components together with

Specifies only maintenance relevant components.

Maintenance BOM’s are primarily used for the following purposes:

Assignment of spare parts

14 | 21 Oct, 2004 | oSAP Program

15 | 21 Oct, 2004 | oSAP Program

Use of generic BOMs (i.e. Material BOMs) rather then specific

Spare Parts will be in SAP as part of the BOM.

16 | 21 Oct, 2004 | oSAP Program

Offers document references and an easy access to related

Access within master data, notifications and work orders.

Requires organized servers and folder structures

17 | 21 Oct, 2004 | oSAP Program

Maintenance relevant materials are for example:

All data of a material is integrated in one master record.

Integration also enables the master data to be used jointly by

In maintenance processing materials are used e.g. in ordering and

Description Example Method

An attribute Pump capacity, 1. Create

Equipment, 3. Link the class to an

Pump capacity: 2000

19 | 21 Oct, 2004 | oSAP Program

Maintenance catalogues are groups of standardized codes used to report

20 | 21 Oct, 2004 | oSAP Program

Technical history associated with the repair and maintenance of

Standardized codes enable benchmarking.

21 | 21 Oct, 2004 | oSAP Program

Catalogue Structure: Example :

22 | 21 Oct, 2004 | oSAP Program

24 | 21 Oct, 2004 | oSAP Program