SAP Plant Maintenance

Presentation By:
Mr. Subhrajyoti Bhattacharjee
B.E., P.G.D.M., PMP®, Certified SAP PM Solution
Consultant
 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

 Government
& Authorities

Vendors Organization Customers

Environment
 External
Vendors
Environment

Organizational ERP
System
Finance &
Controllin
g

Purchasin
Projects
g
Productio
n
Planning
HR &
Payroll
Sales &
Distributio
Maintena n
nce
Government & Customers
Authorities
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
Organization’s 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 Operating
costs and minimize adverse effects on Equipment ,Operating resources and
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

 Company
Centralized Code De-centralized
Planning Planning

Maintenance Maintenance
Planning Planning
Plant Plant

Maintenance Maintenance Maintenance

Plant Plant 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

 Technical
Objects

SAP
Work PM: Planning
Centres Master Objects
Data

Others
 Work
Centre Work Centre Hierarchy is a
Hierarch Grouping of Work centres
y comprising Maintenance Task
Force

Work
Capacity
Centre
Capacity
information
includes: PM Work Centre
Category “0005”

Comprises:
Basic data,
Unit of capacity Default values,
Capacity view,
Start/End times Scheduling view,
Utilizations HR
Assignments,
Shift schedules Costing view
etc.
 Load
Monitoring
Capacity
Planning

Capacity
Leveling

Capacity Functionalities
 Functional Locations Structured into Hierarchical
Levels using Structure
Indicators

Equipment Serial Number

Sub Equipment Material No

Equipment Bill of Material

Component material parts

 Plan
Top Down Bottom up
planning planning

Task List

Maintenance item
 • Single cycle Plans
• Strategy Based Plans
Plans • Counter Based Plans (Single/Multi Counter)

• General Task Lists

• Functional Location Task Lists
Task Lists • Equipment Task Lists

• Standard items
• Strategy based items
Items
Other Master
Data

Measuring
Points/Counters

Class/
Characteristi
cs

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

Maintenance Notifications vs. Maintenance
Orders
 Maintenance  Maintenance Orders
Notifications are are a complete record
Reporting objects to of:
record:  Operations performed
 Maintenance requirement  Components used
 Cause, Object Impacted, (Stock/Non stock)
Tasks due & Activities  Services hired
Performed  Time and costs posted
 Types: Maintenance
 Settlements executed
Request, Malfunction
(Breakdown) Report,  Types: Breakdown
Activity Report, Service Orders, Planned
Notifications Orders, Predictive
Orders, Calibrations
 Maintenance Notifications
Orders, Refurbishment
generally do not record Orders, Capital Work
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

 Master Data
Functional Material Work center
Equipment
Location (Stock parts) (PM & PP)

Production personnel Permits (If Activity Service

follows up on work done
against existing
applicable) Type Master record
Notification

Yes

Further work done is

recorded in
SAP Notification mail to
Existing Notification Notification&
initiator of work
(Report IW29)? Notification Tasks
Technically completed
No

No

SAP Notification mail to Notification user PM Oredr

Maintenance designated Person status changed to Planning done
Equipment breaks Convert to PM Order (Type
Notification (Type responsible in Yes ALWD and (Operation,
down Order? PM01) created
“M2”) created Notification header notification Components,
released Service, Permits)

Shop papers
printed from
PM order
Goods receipt to Storage Issue stock part to Reservation No
location assigned to PM Order

Stock part Yes

Approved purchase Purchase

requisitions converted to requisition created Order user status Assigned permits if
Is stock part Is Stock part
Purchase order (MM side) No Yes changed to PLND any are issued by
available? planned?
and order released relevant personnel

No

Approved
purchase Purchase
Goods receipt against PO requisition
requisitions Is Non – stock
posts costs to associated converted to created within Yes
part planned?
PM order Purchase order PM order
Y

Order settled to relevant No Yes

settlement receiver (Cost
Center)
Approved
Service acceptance Purchase
purchase
throughService entry requisition Is Extenal Is further planning
requisitions
sheet against Service PO created within service required?
converted to
posts costs to associated PM order planned?
Purchase order
PM order

No

Production
Settlement rule defined in User status of
personnel to Time confirmation
order & Order Technically Maintenance order
confirm Order for Manhours with Is Maintenance
completed with details of changed to MTCO – Yes No
completion by suitable Activity work completed?
Malfunction end date/time Completed by
changing user Type
status to PRCO
Maintenance In SAP

Outside SAP
 Master Data
Functional Material Work center Service
Equipment
Location (Stock parts) (PM & PP) Master record

Counter (For
Permits (If Activity Maintenance Maintenance
counter based
applicable) Type Task List Plan
plans)

Measurement Planned Due

document posting dates for order
for Counter Based creation are set in
plans system

Orders generated
Maintenance Plan Scheduling overview for the periodare
Maintenance plan Is next call object – Preventive
created (Single report generated by planned further
Maintenance Task
cycle/Strategy
scheduled Maintenance Order Yes Maintenance order maintenance
List created (Background job/ due? (Type”PM02") (Operation,
based/Counter personnel on a Components,
Manual) generated
based) periodic basis Service, Permits)

Shop papers
printed from
PM order
Goods receipt to Storage Issue stock part to Reservation No
location assigned to PM Order

Stock part Yes

Approved purchase Purchase

requisitions converted to requisition created Order user status Assigned permits if
Is stock part Is Stock part
Purchase order (MM side) No Yes changed to PLND any are issued by
available? planned?
and order released relevant personnel

No

Approved
Purchase
purchase
Goods receipt against PO requisition
requisitions Is Non – stock
posts costs to associated created within Yes
converted to part planned?
PM order PM order
Purchase order
Y

Order settled to relevant No Yes

settlement receiver (Cost
Center) Approved
Service acceptance purchase Purchase
throughService entry requisitions requisition Is Extenal Is further planning
sheet against Service PO converted to created within service required?
posts costs to associated Purchase order PM order planned?
PM order

No

Production
Settlement rule defined in User status of
personnel to Time confirmation
order & Order Technically Maintenance order
confirm Order for Manhours with Is Maintenance
completed with details of changed to MTCO – Yes No
completion by suitable Activity work completed?
Start/end date/time Completed by
changing user Type
status to PRCO
Maintenance In SAP

Outside SAP
 Master Data
Functional Material Work center Service
Equipment
Location (Stock parts) (PM & PP) Master record

Counter (For
Permits (If Activity Maintenance Maintenance
counter based
applicable) Type Task List Plan
plans)

Measurement Planned Due

document posting dates for order
for Counter Based creation are set in
plans system

Maintenance Task Maintenance Plan Scheduling overview Calibration Orders auto

Maintenance plan Is next call object – Preventive
List created created (Single report generated by generated and released
(Inspection point cycle/Strategy
scheduled Maintenance Order Yes Maintenance order maintenance (Operation,
(Background job/ due? (Type”PM02")
300, MIC’s based/Counter personnel on a Components, Service,
Manual) generated
entered) based) periodic basis Permits)

Goods receipt to Storage Issue stock part to Reservation No

location assigned to PM Order

Stock part Yes

Shop papers
printed from
PM order
Approved purchase Purchase
requisitions converted to requisition created Quality Inspection Lot
Is stock part Is Stock part
Purchase order (MM side) No Yes Generated
available? planned?

Order settled to relevant No

settlement receiver (Quality
Cost Center) Approved
Purchase
purchase
Goods receipt against PO requisition
requisitions Is Non – stock
posts costs to associated created within Yes
converted to part planned?
PM order PM order
Purchase order
Y

No Yes

Result recording done Approved

against Inspection Lot, Order Service acceptance purchase Purchase
Technically completed throughService entry requisitions requisition Is Extenal Is further planning
sheet against Service PO converted to created within service required?
posts costs to associated Purchase order PM order planned?
PM order

No

Time confirmation
for Internal
Settlement rule set in Is Maintenance
Manhours with Yes No
Calibration order work completed?
suitable Activity
Type In SAP

Outside SAP
 Master Data
Functional Material Work center
Equipment
Location (Stock parts) (PM & PP)

Permits (If Activity Service

Requestor checks on work
progress
applicable) Type Master record

Yes

Work detailed in
SAP Notification mail to
Notification and Tasks
Existing Notification initiator of work
Technically completed
(Report IW29)?
No
No

Notification user PM Oredr

Scope for correction/ Maintenance SAP Notification mail to
status changed to Planning done
predictive maintenance Notification (Type designated Person Convert to PM Order (Type
Yes ALWD and (Operation,
identified by Operator/ “M1” Maintenance responsible in Order? PM01) created
notification Components,
Maintenance person request) created Notification header
released Service, Permits)

Shop papers
printed from
PM order
Goods receipt to Storage Issue stock part to Reservation No
location assigned to PM Order

Stock part Yes

Approved purchase Purchase

requisitions converted to requisition created Order user status Assigned permits if
Is stock part Is Stock part
Purchase order (MM side) No Yes changed to PLND any are issued by
available? planned?
and order released relevant personnel

No

Approved
Purchase
purchase
Goods receipt against PO requisition
requisitions Is Non – stock
posts costs to associated created within Yes
converted to part planned?
PM order PM order
Purchase order
Y

Order settled to relevant No Yes

settlement receiver (Cost
Center)
Approved
Service acceptance purchase Purchase
throughService entry requisitions requisition Is Extenal Is further planning
sheet against Service PO converted to created within service required?
posts costs to associated Purchase order PM order planned?
PM order

No

Production
Settlement rule defined in User status of
personnel to Time confirmation
order & Order Technically Maintenance order
confirm Order for Manhours with Is Maintenance
completed with details of changed to MTCO – Yes No
completion by suitable Activity work completed?
Start/ end date/time Completed by
changing user Type
status to PRCO
Maintenance In SAP

Outside SAP
 Master Data
Asset Master –
Functional Material Work center
AuC/FxA (As
Location (Stock parts) (PM & PP)
relevant)

Permits (If Activity Service Equipment

applicable) Type Master record (Associated to
FxA)

Asset under Maintenance Team Functional Location (for asset

construction created intimated on the AuC build up created) as reference
New Asset buildup
by Business SAP Number Technical object
Finance Team

Capital work –
New asset build up
or Enhancement
Order Planning
Capital work Order (Type done (Operation,
Existing Equipment No (with
“PM06”) created – with Components,
Asset Enhancement assigned Fixed asset) would
relevant Maintenance Service, Permits),
be identified
Activity type assigned Settlement rule
defined

Shop papers
printed from
PM order
Goods receipt to Storage Issue stock part to Reservation No
location assigned to PM Order

Yes
Stock part

Functional Location Structure Approved purchase Purchase

requisitions converted to requisition created Is stock part Assigned permits if
completed with assigned No Is Stock part Capital order
Purchase order (MM side) available? Yes any are issued by
Equipment tagged to FxA planned? released
relevant personnel
number

No

Approved
Purchase
purchase
Maintenance Team Goods receipt against PO requisition
intimated on the FxA
requisitions Is Non – stock
posts costs to associated created within Yes
converted to part planned?
Number PM order PM order
Purchase order
Y

No Yes

Approved
Service acceptance Purchase
In case of Asset buildup work, purchase
throughService entry requisition Is Extenal Is further planning
Finance finally settles AuC to requisitions
sheet against Service PO created within Yes service required?
a FxA ( created) converted to
posts costs to associated PM order planned?
Purchase order
PM order

No

Time confirmation
On completion of work Order Periodic settlement
for Manhours with Is Maintenance
Technically completed with executed to relevant Yes No
suitable Activity work completed?
necessary details receiver (AuC/FxA)
Type
In SAP

Outside SAP
 Master Data
Ref. Material (with PM Work center
valuation types Serial
Equipment (For Internal
C1, C2, C3) Number Refurbishment)

Batch Numbers for C1, Asset No

Service Activity
C2, C3 states of Ref (Tagged to
material Master record Type
Equipment ID)

Refurbishment order type Order Planning done

“PM04" created for Material (Operation – Internal or
Need for Refurbishment
No, to convert from C3 - External Services, Additional
identified
Damaged to C2 - Components if any),
Refurbished state Settlement rule defined

Shop papers
printed from
PM order
Goods receipt to Storage Issue stock part to Reservation No
location assigned to PM Order

Stock part Yes

Approved purchase Purchase Additional

requisitions converted to requisition created Damaged Material part
Available in Stock parts Order released
Purchase order (MM side) No Yes (valuation type C3) issued to
stock? required/
reservation no. in order
planned?

No

Approved
Purchase
purchase
Goods receipt against PO requisition
requisitions Is Non – stock
posts costs to associated created within Yes
converted to part planned?
PM order PM order
Purchase order
Y

No Yes

Approved
Service acceptance Purchase
Settlement executed to settle purchase Is Extenal
throughService entry requisition Is further planning
order costs (As per business requisitions Refurbishment
sheet against Service PO created within required?
requirement to FxA) converted to service
posts costs to associated PM order
Purchase order planned?
PM order

No

Time confirmation
for Manhours with
On completion of work Order Goods receipt of
suitable Activity Is Maintenance
Technically completed with Refurbished part (val. Type Yes No
Type – In case of work completed?
necessary details “C2") to store
internal manhour
consumed
In SAP

Outside SAP
ERP Systems: An Overview

Plant Maintenance: An Overview

Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios

Integrations, Advanced scenarios, Interfaces & Reports

 Plant Maintenance Controlling
QM Master Employe
Equipments e
Sender Cost Activity
Functional Planned
Notification PM Work Center Types
Location Rates /hr
Financial Center
Accounting Receiver
Cost Center

Maintenance Order
G/L Fixed Equipment Plan Header
Account Asset Material Management
Operation
- Internal
Shutdown Operation
– Services Service Master
PP Work BOM Spares Compone
Center - nt
Machine Material Master
Costs
 PM - Customer Service Scenarios

 PM - Work Clearance Management

 PM – Fleet Management

 PM – Mobile Asset Management

 ** PM – Project Oriented Maintenance

** PM – Linear Asset Management

 ** PM – Rotables Subcontracting

 ** PM – Inspection Rounds

 ** PM – Take over- Hand over of Equipments

** Functionalities available only in ECC 6.0 and in specific EHP versions

SCADA SAP
BW

SAP Plant Maintenance

Others
SAP MI
Maintenance Cost Analysis Report

Wave- I

Wave- II
Man hour Utilization Report

Wave- I

Wave- II
Downtime Analysis Report

Wave- I

Wave- II
MTTR/MTBF Report

Wave- I

Wave- II
Cause and Effect Analysis Report

Wave- I

Wave- II
Preventive Schedule Overview Report

Wave- I

Wave- II
Material Goods Movement/Consumption Report

Wave- I

Wave- II
Thank you !!