What is SAP Plant Maintenance Module

Plant Maintenance (PM) operates the overall maintenance business processes and functions.The Plant Maintenance module allows a maintenance organization to: Identify, document, and correct failures and degradations of any equipments for which they have maintenance responsibility. Plan and schedule activities to prevent or predict failures and keep assets and processes operating within design specifications. Both Corrective and Preventative maintenance processes exist in the Plant Maintenance module. Corrective maintenance refers to the activities conducted by the Maintenance Organization to repair equipment of all forms within their area of responsibility. Preventive maintenance is a discipline that uses processes and activities that focus on the prevention of failures or performance degradation before it occurs. Plant Maintenance is closely integrated to MM, FICO and PP Module.

Beneifits of SAP Plant Maintenance Module Implementation

The following benefits you can get from sap PM Module. 1. Each and every equipment and fleet object (like compressor, Motor, Truck, Ship, Pay loader) maintenance activity you can get from the system. details and their

2. Break down maintenance, Its causes and duration recorded into the system.(from Notification) 3.Maintenance activity like maintenance duration, planning, Operation,labor and material involvement (from maintenance order). 4. Early warning system enabled automatically before preventive maintenance (with Strategy, Task List, Material etc). 5. Easy tracking of malfunctioning, breakdown and preventive maintenance activities. 6. Equipment material and servicing costing analysis report. 7. You can maintian the equipment log sheet online.,like boiler temperature reading etc. (from measuring documents). 8. You can integrate with Quality module and monitor calibration maintenance. NB: This above activities are presently followed in most organizations in Bangladesh. But lot of maintenance process can be done from PM. Over all your information about the maintenance is online and you can maintian paper less environment by SAP Plant Maintenance.

Beneifits of SAP Plant Maintenance Module Implementation

The following benefits you can get from sap PM Module. 1. Each and every equipment and fleet object (like compressor, Motor, Truck, Ship, Pay loader) maintenance activity you can get from the system. details and their

2. Break down maintenance, Its causes and duration recorded into the system.(from Notification) 3.Maintenance activity like maintenance duration, planning, Operation,labor and material involvement (from maintenance order).

4. Early warning system enabled automatically before preventive maintenance (with Strategy, Task List, Material etc). 5. Easy tracking of malfunctioning, breakdown and preventive maintenance activities. 6. Equipment material and servicing costing analysis report. 7. You can maintian the equipment log sheet online.,like boiler temperature reading etc. (from measuring documents). 8. You can integrate with Quality module and monitor calibration maintenance. NB: This above activities are presently followed in most organizations in Bangladesh. But lot of maintenance process can be done from PM. Over all your information about the maintenance is online and you can maintian paper less environment by SAP Plant Maintenance.

PM Functional Location Configuration Part 1.

Path: IMG > Plant Maintenance and Customer Service> Master Data in Plant Maintenance and Customer Service > Technical Objects > Functional Locations > Create Structure Indicator for Reference Locations/Functional Locations (T-Code: OIPK) Click New Entries

Strlndicator : Length Maximum 5 Character. StructlndText : Indicator Name maximum 40 Character. Edit Mask : Used for Identification character, numeric or both.

You can use the following signs when structuring the block: "A" only letters can be entered "N" only numbers can be entered "X" both numbers and letters can be entered "S" numbers, letters, and special characters can be entered The following special characters are allowed: &()+,./:;<=> The following signs can be used to divide the blocks: - hyphen / slash ' ' blank . period _ underscore = equals sign + plus sign ; semicolon The following Functional location created by this structure indicator is alpha and numeric (both). > Define Category of Reference Functional Location

> Define Category of Functional Location

> Define Structural Display for Reference Functional Locations (T Code: OIWR)

> Define Field Selection for Data Screen for Reference Functional Locations (T Code : OIAJ)

> Define Structural Display for Functional Locations (T Code : OIWP)

> Define Field Selection for Functional Locations.

Screen Group: Place Specific

Screen Group: Data for Technical Objects ( TCode : OIAF)

PM Functional Location Configuration Part 2.

IMG > Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service > Technical Objects > Functional Locations > Field Selection for Multi-Level List Displays of Functional Locations T Code (OIX2)

> Define Field Selection for Equipment Usage Data Fields (T Code OIX3).

> Define Field Selection for Equipment Master Data Fields (OIX4)

What is SAP PM Equipment.

Equipment is in Plant Maintenance. Equipment is technical object that is to be maintain individually. Different types of equipment's are.. Production Equipment's (Pump, Motor etc). Production Resource Tools (Cranes, Tools) Mechanical Equipment (Shape Machine, Gear Box, Conveyor, Hopper etc) Electrical Equipment ( Distribution Power Panel, Transformer, Generator etc). Machinery ( Lathe Machine etc) Civil Equipment's ( Mixture Machine, Brick Crush Machine etc) Fleet Equipment ( Trucks, Pay loader, Ship, Dump Trucks etc)

Purpose : Management of individual data. Recording of Maintenance Tasks. Cost of Maintenance Tasks (Labor, Material) maintain individually. Evaluation of technical data. Recording of usage times. Tracking physical objects as Assets.

Equipment Master Data : Equipment's can be maintain hierarchy .....Superior Level and Sub Level.

Equipment is SAP. Imp T Code : IE01(Create) , IE02 (Change), IE03 (Display), IE05 (List Display : Change), IE31 (Create Fleet Object ) Equipment Master Data Properties: General Tab:

Location Tab :

Organization Tab:

Structure Tab :

Warranty and Specification :

PM Equipment Configuration Part 1

IMG Path: Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service > Technical Objects > Equipment > Equipment Categories > Maintain Equipment Category

Click

Fill Up the following fields for a Civil Category

Then

A Equipment Category will be created. Next Step : This Category will assign to a Group with Number Range.

PM Equipment Configuration Part 2.

IMG Path: Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service > Technical Objects > Equipment > Equipment Categories >Define Number Range (T Code : OIEN)

First click on overview tab, here you can check the present Categories, Groups and Numer Ranges.

Here we can see the Category C . Now we will make a Group with Number Range.Then Category C will be assigned to this group. Make a Group with Number Range Click Groups Maintain Tab or Press F6

Then Click Group > Insert From Menu

New Form will appear, here you have to fill up Group Name, From number an To number range.

Press

Press Enter and Save. New Group is created named Civil with number range. Now we will assign category C (Civil, that we have created previously "look EQ config part 1") to this Group Civil. Assign Category to Group Click

Then Click the Check button on Groups (Civil), Click Category C and then click Select Element or Press F2.

Then Edit > Assign Element Group from Menu.

Now Category will assign to this group.

Then Save. Now Equipment Category made with a group and number range.You can check it by overview tab.

> Equipment Types (T Code : OIEA)

Then Save. A equipment type will be added.

PM Equipment Configuration Part 3

Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service > Technical Objects > Equipment > Equipment Usage Period > Usage History Update

> Define History-Related Fields T Code (OIEZ)

Define Installation at Functional Location.

>Assign Partner Determination Procedure to Equipment Category (T Code : OIEV)

>Define Field Selection for the Equipment Master Record

Field Selection for Equipment-Specific Fields (T Code : OIAD)

Field Selection for Equipment (Common Fields for Equipment/Funct. Location)(T Code : OIAF)

>Allow Multilingual Text Maintenance for Each Equipment Category

>Set List Editing for Equipment

Selection screen list display/Change/Maintain Field Selection list mode (T Code : OIYC)

This all fields have to maintain on your business requirements. Define Field Selection for Multi-Level List Displays of Equipment Define Field Selection for Equipment Master Data Fields ( T Code : OIXC)

Define Field Selection for Equipment Usage Data Fields (T Code : OIXD)

PM Fleet Objects and Configuration Process

What is Fleet Objects in SAP PM ? In

SAP System commercial vehicles, buses, trains, trucks, loading vehicles (pay loader, excavator, dump trucks) cranes, machinery, ships, airplanes and helicopters and so on treated as a Fleet Object and maintain by Fleet Management System. Fleet objects are similar as an Equipment with vehicle-specific additional data, which is displayed in the system on two additional tab pages. Here you can specify important fleet data such as the license plate number, load volume, consumption data, fuel card number, engine data, or fuel type and so on directly in the equipment master record. We can use the fleet object as a reference object for Maintenance Notification, Maintenance Order or Service Tasks.We can also perform maintenance planning date of the next scheduled service dependent on the distance counter (for example, the odometer), the time counter (for example, the time meter), or any other fleet counter. T Code Create: IE31

SAP Internal Order process can be connect by settlement rule while creating a maintenance order. Configuration Path: Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service > Technical Objects > Settings for Fleet Management > Assign View Profile and Equipment Categories to Fleet Object Types Select any Object Type (have to create before) and set here as a fleet.

Save Definition of default equipment category Click New Entries

Save > Define Consumable Types

> Define Usage Types for Fleet Objects

> Define Engine Types for Fleet Objects

> Make Settings for Units of Measurement for Monitoring of Consumption

> Define Special Measurement Positions for Fleet Objects

> Define Calculation Method for Fleet Consumption Values

> Set Field Selection for Specific Fields in Fleet Management

NB: Dear viewers, I have shown you what elements are involve in Fleet Management. I will explain and update this part later.

SAP PM General Data Configuration Part 1

IMG Path: Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service >

Technical Objects > General Data > Define Types of Technical Objects.

Create a Object Type and its description and Save. > Define Plant Sections (T Code : OIAB)

Plant Section is a division of maintenance plants in to Production areas. Machines or sets of machines that are represented in the system as pieces of equipment or functional locations are installed in Plant Sections.

> Define Planner Groups (T Code : OIAI)

Planner group is a group of employees responsible for planning and processing maintenance tasks in a plant.

> Define ABC Indicators (T Code : OIAA) ABC Indicators are used to define the importance of the technical objects

> Define Authorization Groups (T Code : OIAG) Authorization groups are used to categorize similar objects from the point of view of authorization. Example : Mechanical, Electrical, Automobile, Civil etc.

Define Locations ( T Code : OIAS)

Then Save..You can skip this Part..

End Of Part 1

SAP PM General Data Configuration Part 2

IMG Path : Plant Maintenance and Customer Service > Master Data in Plant Maintenance and Customer Service > Technical Objects > General Data > Set View Profiles for Technical Objects This Customizing activity allows you to create individual screens for technical objects. The data fields for the technical objects are sorted by contents into screen groups. It is possible to define one or more view profiles for each screen group, for example, Equipment. Each view profile enables you

to assign pre-grouped and accompanying fields to individual screen templates. These screen templates can be labeled individually using tab pages. To make the tab pages visible in the maintenance transactions, they must be labeled as active. You can assign a view profile to each equipment category or functional location category, and to each fleet object type. Screen Group Equipment Data T Code (S_ALR_87009237) ( I have just shown what is this configuration, You can create it by New Entries)

Select Screen group equipment data and double click on Activity and Layout of views.

Here You can See under Description "General, Location, Organization, Structure and Additional data 1. Number 10. General will show the General Tab for Equipment Master data , that contains Screen no 005, 010 and 015 show at below....

Number 20, Location Tab Contains Screen No 20 and 25, Number 30 Organization Tab contains screen 30 and 35, Number 50 Structure Tab contains screen 40 and 45 and lastly Number 60 Additional Data 1 contains 110 and 97 screens. Click Icons and texts of views

Here Additional Data 1 renamed to Warranty and Specification Tabs. In this Configuration you can see the effects below....

Location Tab :

Screen Group Functional Location Data.

Screen Group Fleet Object Data

> Define Object Information Keys (T Code : OIMD)

Work Center and Cost Center in SAP Plant Maintenance.

Work Center: A work center is a particular place or geographic location where Maintenance Operation carried out. Work center could represent a particular workstation with specific tools and equipment on a specific floor of a specific building. Example.. MECH : Mechanical Work Center. ELEC : Electrical Work Center T Code : IR01, IR02, IR03 IR05. The work center has an available capacity. The activities performed by the work center are valuated by charge rates, which are determined by cost centers and activity types. Work centers can be: Machines People (Labor, Expert etc) Production lines Groups of craftsmen Use Work centers are used in task list operations and work orders. Data in work centers is used for ...... Scheduling

Operating times and formulas are entered in the work center, so that the duration of an operation can be calculated. Costing Formulas are entered in the work center, so that the costs of an operation can be calculated. A work center is also assigned to a cost center. Capacity planning The available capacity and formulas for calculating capacity requirements are entered in the work center. Simplifying operation maintenance Various default values for operations can be entered in the work center.

Cost Centers : Cost Centers are Cost Collector in SAP. Its tracked costs are individually. Example: Department Mechanical have one Cost Center named BICLMECH. T Code : KS01.

Create Functional location and its related Configuration.

First have a Look on PM Functional Location Structure by T Code : IH01.

Click Execute Button. You can See the available Functional Locations.

Now we will create a new functional location. That will be BICL-CWS (BICL Civil Workshop). So it will create based on Hierarchy Level 1and 2. [1 H.key for BICL(Edit Mask = SSSS) and 2 H.key for CWS(Edit

Mask = SSS)].

Please Check Configuration or T Code OIPK. Create Functional Location : T Code IL01 .

Here I input Functional Loc = BICL-CWS and Select Strindicator = BICL.

Now Functional Location Description = BICL Civil Workshop. Then have to input General Tab data. General Tab Contains 3 Screens (Green Marked) 1. General Data 2. Reference Data and 3. Manufacture Data. You can See the Configuration Process here Or You Can Check by T Code : S_ALR_87009237.

Lets See the Screen Group (Yellow Marked) : Functional Location data, That Contains screen no 005,010 and 015 that we see as 1.General data 2. Reference Data and 2. Manufacture Data Screen. Now I select Object type (Ex. Crusher), Authorization Group : BICV = BICL Civil (Config T Code : OIAG).

Select Location data (Config T Code OIAS), Plant Section data (Config T Code OIAB), Work Center Data(Create T Code: IR01) and ABC Indicator (Config T Code OIAA). Then Organization Tab:

Select asset (if required asset number), Cost Center (Create by FICO T Code KS01), Planning Plant, Planner Group and Main Work center etc.

Then select Superior functional location, Position etc and save. Functional Location will Create. Now Check It By IH01. Next Topic : Equipment Create and Installed under this Functional Location.

Create PM Equipment and Its related Configuration.

Create Equipment T Code : IE01. First have a look the structure by IH01.

Under Functional Location BICL-CWS there in no Equipment Installed. We will create a Equipment and install it under BICL-CWS Functional Location. STEP 1 T Code IE01 and press Enter. Select Category C for Civil and press Enter.

For Configuration Process Click here and here

Select Functional Location like BICL-CWS Then Enter and SAVE.

Massage will come in Status Bar Like : Equipment created with the number 7000001. Click on this. So, Equipment is Created.

Step 2 : Check Now Check the Equipment by IH01. You will find your equipment under Functional Location.

You can find Equipment Configuration here.

SAP Plant Maintenance Process Flow.

Order Processing : Stock Material

Order Processing : Non Stock Material

Order Processing : Malfunction Maintenance.

Order Processing: External Service Maintenance

SAP PM Notification
What is SAP Plant Maintenance Notification ?

Notifications are the tool we use in exceptional operational situations in maintenance processing to: - Describe the technical emergency situation of an object. - Request a required task in the maintenance processing. - Document the work performed. - Document maintenance tasks and make them available for analysis in the long term.

Notification mainly contains technical information and practically no integration points with other SAP applications, so it does not contain information about any costs. When we Create a Notification ? When we need to report a problem, request for maintenance work or record an event or activity. Notifications result from phone or electronic communication, as well as observations. Example : Some abnormal sound/Problem occurred in a machine or breakdown, So need notify to concern. Notification Elements: Equipment, Functional Location, description, reported by, work center etc. Notification Types: SAP predefined three notification types in the standard system: Activity report: (for documenting performed actions) An activity report describes a maintenance or service activity already performed, or one that was not the result of a malfunction or damage. It simply provides technical documentation of
which activities were performed when and with what results. Activity reports are therefore used for the technical confirmation of maintenance or service activities.

A typical activity report, for example, is the inspection findings, since it describes the results of an inspection to test the actual condition of the object. In most cases,the inspection task is based upon an inspection order. Another typical activity report is the maintenance findings. This documents the technical values of the object that are determined during and/or after planned maintenance work. This maintenance work is performed in order to maintain the ideal condition of the object, and always
results from maintenance plans.

Typical examples of the activities documented in activity reports are "Fill up oil", "Check pressure" or "Tighten screws". Applicable: Which activity you performed Where you performed the activity What effects it may have (had) What the extent of the activity was The activity report differs from the malfunction report or customer notification in that no malfunctions or problems need to be described, only the activities that were performed. Malfunction report: (For information about malfunctions and problems that occur.) A malfunction report describes a malfunction at an object that affects its performance in some respect.

For example, an employee from production would use a malfunction report to report that: A technical system is not functioning properly Performance has reduced for a technical system, or that the system is not functioning at all A production system is producing goods of poor quality As a rule, a malfunction report requires the maintenance department to arrange for a specific repair task to be performed, for the ideal condition of the object to be restored. Applicable: As a rule, most companies only record the malfunction, damage or problem initially, in other words, only data relating to the malfunction are entered in the notification. Data referring to the repair and to technical findings is usually only entered as a second step in the system, that is, as changes to the notification.
A special case of malfunction report is when a machine operator determines a malfunction, immediately repairs it and subsequently documents the malfunction that occurred, its effect and the way in which it was rectified. In this case, the maintenance notification is created as a completion confirmation once the maintenance tasks have been completed.

When you create a malfunction report, you should provide the maintenance planning department with as much information as possible regarding the malfunction or problem. To do this,
make the following entries where possible:

Which malfunction or problem has occurred Where the malfunction or problem has occurred What effect it has Who reported the malfunction or problem What further damage or problems have been caused Maintenance request: (For requesting tasks to be performed.) A maintenance request is a targeted instruction to the maintenance department to perform an activity in the manner described. The decisive factor in this case is that there is no
malfunction.

Maintenance requests are typically used for investments, for example if an employee requires a new monitor, or if all the telephones in one part of the building in a company need
replacing. All that is initially important in the maintenance request is the maintenance activities. Data relating to the execution of the tasks is only entered in the system in a second step, by changing the maintenance notification.

When creating a maintenance request you should provide as much information as possible for maintenance planning, regarding the activities you want the maintenance department to
carry out for you. To do this, make the following entries where possible:

 What is being requested The object or area to which the request refers Who requested the activity General (User Specific) : A user-specific notification is one that does not belong to one of the standard notification types. This is the case if your company uses individual notification types.A user-specific notification type is based on the standard notification type. You can
configure the screens in Customizing

You can convert Notification to Maintenance Order as your requirements (If needed to involve Maintenance Task, Material, Purchase Requisition etc). Notification Characteristics: A notification has the following characteristics: Header data :Each notification has header data. This includes information that is used to identify and manage the notification. It applies to the complete notification. Notification item: You enter and maintain the data in a notification item to identify in more detail the problem or damage that occurred or for the executed action. A notification can have several items. Actions: Actions document the work performed for a notification. They are particularly important in inspections to provide evidence of the work performed and the results established. Task data:Task data describes activities that still have to be performed and may only have resulted from implementing the maintenance activity (Example Creating Report).
Notification Contents: Reference object: (equipment, functional location, assembly, material serial number) Subject : (For Adding Text. You can add Notification Related information) Responsibilities: (for example, planner group, main work center) Item and cause : (for example, damage, cause of damage, object part) System availability: (for example, system availability before/after) Malfunction data : (for example, breakdown, start/end/duration of breakdown) Start/end dates : (for example, priority, required start, required end) Item overview : (for example, assembly, text) Activities : For notification header and notification item Tasks: For notification header and notification item Causes: For notification header and notification item Partner overview: (for example, partner role, partner , address) Warranty: (for example, start/end of warranty) Location: (for example, maintenance plant, cost center, business area) Used T Code : IW21 (Create), IW22(Modify), IW23(Display), IW25, IW27(Assigned Deletion Flag)

IW28 (Change: List), IW29 (List Display).

SAP PM Notification Configuration. Part 1

Create Notification Type: (T Code OQN0) IMG Path : Plant Maintenance and Customer Service > Maintenance and Service Processing > Maintenance and Service Notifications > Notification Creation > Define Notification Types

Catalogs for Notification Tyes (T Code: OQN5) IMG Path : Plant Maintenance and Customer Service > Maintenance and Service Processing > Maintenance and Service Notifications > Notification Creation > Notification Content > Maintain Catalogs (Define Catalogs/Edit Catalogs)

Define Catalog Profile (T Code : OQN6) IMG Path : Plant Maintenance and Customer Service > Maintenance and Service Processing > Maintenance and Service Notifications > Notification Creation > Notification Content >Define Catalog Profile

Display Catalog Directory with All Sub-Items IMG Path : Plant Maintenance and Customer Service > Maintenance and Service Processing > Maintenance and Service Notifications > Notification Creation > Notification Content >Display Catalog Directory with All Sub-Items

Cataqlogs and Catalog Profile for Notification Type : IMG Path : Plant Maintenance and Customer Service > Maintenance and Service Processing > Maintenance and Service Notifications > Notification Creation > Notification Content > Change Catalogs and Catalog Profile for Notification Type

Define Number Ranges: (T Code IW20) IMG Path : Plant Maintenance and Customer Service > Maintenance and Service Processing > Maintenance and Service Notifications > Notification Creation > Notification Types > Define number ranges

Assign Notification Types to Order Types (T Code OIM3)

(First have to Create Order Types and then assign to here)