Click to edit Master title style
Process Excellence
SAP PLANT MAINTENANCE
“Your Trusted IT Partner”
Click
SAP R/3toERP
edit Master title style
Accounting Area
Financial accounting (FI)
Controlling (CO)
Asset Accounting (FI AA)
• Human Resources
HR
• Logistics
Production Planning (PP)
Materials Management (MM)
Sales and Distribution (SD)
Quality Management (QM)
Service Management (SM)
Plant Maintenance (PM)
Click
SAP to edit Master
Organizational title style
Structure
PM Overview
Click to edit Master title style
Plant Maintenance Introduction
Plant Maintenance Organization
Technical Objects
Break Down Maintenance
Corrective Maintenance
Refurbishment Of Spare Parts
Preventive Maintenance
Work Clearance Management
Click
Plant to edit Master
Maintenance title style
Introduction
SAP Plant Maintenance automates the process of
performing facility repair and maintenance requests.
For example,. SAP records a problem that is reported,
labor and materials are planned, costs are recorded,
and then costs are settled
Plant Maintenance operates the overall maintenance
business processes and functions allows a
maintenance organization to:
Identify, document, and correct failures and
degradations of any assets for which they have
responsibility.
Plant Maintenance
Click Process
to edit Master Flow
title style
Plant Maintenance
Click Process
to edit Master Flow
title style
PM Process Flow Notification
Maintenance Order
Plan
Control
Schedule
Execute
Complete
Plant Maintenance
Click Process
to edit Master Overview
title style
Click
Plant to edit Master
Maintenance title style
Organization
Plant Maintenance Organization
1) Overview of Processes and Available Solutions
Lifecycle of technical Asset
• Investment Planning
• Projects Definition
• Selection of Vendor
• Plant Maintenance
• External Procurement
• shutdown
Click
Plant to edit Master
Maintenance title style
Organization
Plant Maintenance Organization
Master Data
Characteristics Cost Records Bill of Material
Classes Cost Center
Tasks List
Equipment/Functi Maintenance Maintenance
onal Locations Work Centers Strategies
Planning
Maintenance Maintenance
Notifications Plans
Maintenance Purchase
Order Processing
Order Requisition
Material
Reservation Capacity Load
Purchase Order Goods
Material Issue /Release Order Receipt/Invoice
Time
Conformation Receipt
Click
Plant to edit Master
Maintenance title style
Organization
2) User Interface
Various methods that user connects to SAP
Power User
Sporadic User
3) Organizational Levels In Plant Maintenance
Depending on the Company Structure
Maintenance
planning is either of following type
• Plant-Based (Decentralized)
• Cross-Plant (Centralized)
Click
Plant to edit Master
Maintenance title style
Organization
3) Organizational Levels In Plant Maintenance
Analyze Existing Company Structure
Define Maintenance Plants/Planning Plants
Assign Planning Plant/Work Center
Maintenance planner groups are assigned to
planning plants
Maintenance work centers are assigned to
maintenance plant
Click
Plant to edit
Based Master titleStructure
Organization style
Plant Based Organizational Structure
Click
Plant to edit Master
Maintenance title style
Organization
Maintenance Plant & Planning Plant
The plant, at which the operational systems of a
company are installed, is called the maintenance
plant.
If the maintenance work is planned at this plant, the
maintenance plant is also the maintenance planning
plant.
A maintenance planning plant is the organizational
unit in which maintenance requirements are
planned.
Click
Plant to edit Master
Maintenance title style
Organization
Maintenance Planning Plant Structure
Click
Plant to edit Master
Maintenance title style
Organization
Planner Group
The planners within a maintenance planning plant
are defined by maintenance planner groups.
The units of capacity in Plant Maintenance are
managed as maintenance work centres in the PM
system.
The maintenance work centres are usually assigned
to the maintenance planning plant.
Work
ClickCenters
to edit Master title style
Work center is an organizational unit where work is
carried out.
Ex: Machine, Group of machines or group of persons.
Work centres belong to the master data in PM and
provide the capacity required to perform a task.
The basic data contains general data such as work
centre category, description, responsibility, and usage
Work centers can be linked to:
Cost Centers, Positions, People
Work
ClickCenters
to edit Master title style
Functions:
Costing : To determine the costs of an internal
activity by a product unit
Scheduling : To determine the dates when
operations should be performed.
Capacity Planning : The capacity requirements for
the operations in the orders are determined
Click toObjects
Technical edit Master title style
Technical Objects
1) Functional Locations
Functional locations are elements of a technical
structure . We create Functional Structures if we want
to represent systems or operational structures within
our company according to functionality.
Create functional locations hierarchically, and can
also structure them based on the following criteria:
Spatial Ex: Buildings.
Technical Ex: Press or Press Hydraulics
Process-related Ex: Polymerization,.
Click to edit
Functional Master
Location title style
Creation
Functional
Click to Location Structure
edit Master title style
Functional Locations
Functional
Click to Location Structure
edit Master title style
Functional Locations
The main Aim of creating Functional Locations is to
Structure a technical System or building into units that
are relevant to Plant maintenance.
Click to edit
Functional Master title style
Location
Structure Indicator
The identification for functional locations is
created using the structure indicator. The structure
indicator consists of two input fields:
Edit mask : The edit mask is used to control which
characters may be used for identification (letters,
numbers, or both) and how these characters are
grouped together or split.
Hierarchy levels: The hierarchy levels are used to
define which level ends at which character and how
many hierarchy levels the structure may contain.
Functional
Click to Location Structure
edit Master title style
Functional Locations
A functional location can be identified using a maximum
of 40 characters (= maximum length of the edit mask).
Equipment
Click to edit Master title style
2) Equipment
A piece of equipment could be part of bigger technical
structures or independent
Piece of equipment is usually represented as single
object(Ex: Pumps, motors, vehicle) for which
maintenance tasks should be performed.
Equipment
Click to edit Master title style
Create an equipment master record for a technical
object if: You need to manage individual data for
the object
Breakdown, prepared or preventive maintenance task
are required for an object and must be recorded
Technical data for this object must be collected and
evaluated over long periods of time
The costs of maintenance tasks for this object are
to be monitored
Record the usage time of this object at functional
locations
Purpose of edit
Click to Equipment
Master title style
Functional Locations
The time-based data can be used to monitor a piece
of equipment dynamically, that is, track changes to the
equipment over a specific period of time.
Equipment
Click to edit Master title style
2) Equipment
This role contains all the functions that you require to
process equipment.
Equipment Activities in Plant Maintenance (PM)
Creating a piece of equipment (generally, as
production resource/tool, fleet object)
Collective entry for equipment
Changing a piece of equipment
Data transfer from equipment
Taking up data transfer
Bill Of Material
Click to edit Master title style
Functional Locations
Bills of material are used for different purposes. The usage
depends on the enterprise area
Bill Of Material
Click to edit Master title style
3) BOM
The Production Bill of Materials represents a
finished product (parent )made up of different
inventory components (children). During the
production process, you turn the components into the
finished product.
Components in the production bill of materials are
physical items (for example a screw, a wooden board,
a measured quantity of lubricant or paint), or virtual
objects (one work hour)
Bill Of Material
Click to edit Master title style
3) BOM
The engineering/design bill of material includes all
the elements of the product (from an engineering
viewpoint) and contains the technical data. It is
usually not dependent on the order.
The costing bill of material reproduces the product
structure and forms the basis for automatic
determination of the material usage costs for a
product. Items that are not relevant for costing are
not included in this bill of material.
Bill Of Material
Click to edit Master title style
3)BOM
The maintenance bill of material has three important
functions:
It only contains items relevant to Plant Maintenance.
Structuring of the object : The structure of an object should
be displayed as clearly as possible from a maintenance
viewpoint.
Spare parts planning in the order: If a bill of material exists
for a technical object, it can be used during the planning
process of a maintenance order for the purpose of spare
parts identification and planning.
Spare parts planning in the task list: Spare parts can be
planned in the task list based on a bill of material
Bill Of Material
Click to edit Master title style
3)BOM
Instead of a uniform bill of material, these areas use
"their own" bill of material with area-specific data
(for example, production).
They only evaluate bills of material containing area-
specific data. This results in a targeted bill of material
explosion, whereby only the area-specific data is
made available.
Bill Of Material
Click to edit Master title style
3) BOM
Categories of BOM’s are
Material BOM
Equipment BOM
Functional Location BOM
A material BOM is a bill of material that is first
created for a material independently of a
technical object. To do this, material creation is
must.
Create a material BOM for the material
Bill Of Material
Click to edit Master title style
Functional Locations
Break
Click Down
to editMaintenance
Master title style
Break Down Maintenance
Using this business process we can report, perform,
and document maintenance tasks that arise suddenly.
All the resources used, costs, and technical details of
the maintenance task are recorded centrally and can
then be evaluated.
Usually this process is relevant if a technical asset
exhibits a defect, for example, if a pump is leaking or a
printer is not printing properly.
Break
Click Down
to editMaintenance
Master title style
Diverse employees can create a maintenance
notification to report the defect.
The responsible maintenance technician receives
these notifications in his or her work list and makes
the necessary repairs.
Process Flow
1.Notification & Scheduling
2. Execution
3. Completion
Break Down
Click Maintenance
to edit Master title style
Break Down Maintenance Flow
Break Down Maintenance
Break
Click Down
to editMaintenance
Master title style
Create / process notification
Generate work list for notifications
Create / process order
Confirm time
Modify technical object structure
Process Execution
complete order
Refurbishment Of Spare
Click to edit Master titleParts
style
Refurbishment of spare parts:
In a company ,Defective or warn-out spare parts in
storage should be refurbished.
Refurbishment Process
Pre Requisites for Refurbishment in Material Master
Separate Evaluation
Refurbishment Order
Check the effects of refurbishments on stock value
Refurbishment
Click to editProcess
Master title style
Break Down Maintenance
Refurbishment Of Spare
Click to edit Master titleParts
style
Refurbishment of spare parts:
During the refurbishment process, equipment is
maintained by a team of maintenance planners,
maintenance technicians, and store persons.
After a maintenance technician has determined and
replaced the defective equipment, the maintenance
planner posts the defective item to stock
After planning has been posted, the maintenance
planner creates and releases a refurbishment order
for the given items.
Refurbishment Of Spare
Click to edit Master titleParts
style
Refurbishment of spare parts:
Calculated the time and material resources are neede
for the refurbishment.
The order is conformed and Completed.
The stock value changes dynamically according to the
condition of the items, with the price of a refurbished
item covering all internal and external material and
labour costs spent on refurbishing.
Preventive Maintenance
Click to edit Master title style
Preventive Maintenance
Preventive maintenance work is performed to ensure
optimal operation of equipment & avoid costly
unplanned equipment failure or shutdown.
To keep down times and maintenance costs
minimum, the technical systems are inspected and
maintained regularly
Preventive Maintenance Can be followed by 3 Factors
Time Based
Performance Based
Condition based
Preventive Maintenance
Click to edit Master title style
Preventive Maintenance
Time Based
In time-based preventive maintenance, the
maintenance tasks are planned and performed
depending on the time-dependent intervals
determined. (Ex ,Every 6 months)
Performance-Based (Performance)
This preventive maintenance, tasks are triggered
after a specific performance level has been reached
(Ex, Every 10,000 kms)
Preventive Maintenance
Click to edit Master title style
Preventive Maintenance
Condition Based
If the service life is exhausted or if the asset is no
longer in good enough condition to perform its
service to the required quality
Then the service life must be restored through
maintenance or repair work. These maintenance
tasks are generated and performed based on a
certain asset condition.
Preventive
Click to Maintenance
edit Master title style
Preventive Maintenance
Break Down Maintenance
Preventive Maintenance
Click to edit Master title style
Task Lists
In the company, all inspection and maintenance tasks
that must be performed at regular intervals are
defined in maintenance task lists.
Task list header data
Maintenance Planning
Single Cycle Plan (Same activity at regular
intervals)
Strategy (Maintenance work performed in
different cycles)
Maintenance strategy
Preventive Maintenance
Click to edit Master title style
Preventive Maintenance
Process in Detail
Create / process notification
Generate work list for notifications
Create / process order
Plan and schedule order
Perform work clearance management
Confirm time
Perform evaluations in plant maintenance information
system (PMIS)
Corrective Maintenance
Click to edit Master title style
Corrective Maintenance
Maintenance actions carried out to restore a defective
item to a specified condition
5 Phases of corrective Maintenance
Entering Requirement(Notification)
Planning Orders with Operations and Materials (Planning)
Monitoring the cost (Control)
Performing the tasks(Execution)
Completing the Order and Notifications.(Completion)
Corrective
Click toMaintenance
edit Master title style
Corrective Maintenance
Break Down Maintenance
Corrective
Click toMaintenance
edit Master title style
Corrective Maintenance
ACTIVITIES are work performed for Notifications.Importent for inspection,
they prove that certain tasks have been performed.
TASKS: Describes the Activities that still have to be performed.(Also used for
planning purpose)
Corrective Maintenance
Click to edit Master title style
Corrective Maintenance
5 Phases of corrective Maintenance
Entering Requirement(Notification)
Planning Orders with Operations and Materials
(Planning)
Monitoring the cost (Control)
Performing the tasks(Execution)
Completing the Order and
Notifications.(Completion)
Corrective Maintenance
Click to edit Master title style
Corrective Maintenance
Notification: is the technical object contains the
description about the malfunction or requirement
Malfunctions and other requirements are recorded in
notification, notifications can be accessed and
processed via a list
Planning : In this phase orders are created and
planned on the basis of the reported requirements.
Planning compasses the Work to be performed , and
the material required.
Corrective Maintenance
Click to edit Master title style
Corrective Maintenance
Control: In this phase order runs through the different
phases such as material availability check, capacity
planning.
Execution: Order is executed in this phase, Required
material for the order is withdrawn.
Completion: Technical Conformation and Technical
completion.
Work
ClickClearance Management
to edit Master title style
Work Clearance Management
This business process to enforce all safety measures
that must be enforced before inspections, repairs, or
preventive maintenance work are performed.
Maintenance Workers operate in a dangerous
Environment(Ex: High Voltage, Radio Activity).
The WCM component helps company to control and
monitor safety measures.
Helps to ensure and secure working conditions for
plant maintenance employees.
Work Clearance
Click to edit Management
Master title style
Work Clearance Management
Break Down Maintenance
Work Clearance Management is integrated into the Plant
Maintenance (PM) component
Work Clearance
Click Management
to edit Master title style
WCM Process Flow (1)
Order Create Order
Work Clearance Plan Order/ Request Tag
Application Out
Work Clearance Specify Object containing
Document
Tag out/Lockout
Break Down Maintenance
Work Clearance Approve and Perform
Document
Tag out/Lockout
Work
ClickClearance Management
to edit Master title style
Work Clearance Management
Lockout-Tag out (LOTO) or lock and tag is a safety
procedure which is used to ensure that dangerous
machines are properly shut off and not started up
again prior to the completion of maintenance or
servicing work
Work Clearance Document: This document contains a
detailed description of lockout / tag out .
Work Clearance
Click Management
to edit Master title style
WCM Process Flow (2)
Release Order Release Order
Determined
Work Clearance Completing Tagging
Application
Work Clearance Perform Un-tagging
Document
Break Down Maintenance
Order Technically Completing
Completion
Order
Click to edit Master title style
QUERIES ?
Click to edit Master title style
THANK YOU
