Workshop Plant Maintenance with SAP PM

Assets
What are we talking about?

technical view

sales view

SAP
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Main aspects of the PM System

Structuring assets/material data

Planning

Implementation / Documentation

History / analyses

of maintenance steps

Techincal view
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Sales view
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Integrated maintenance with PM

Module PM
Maintenance

Module FI
Assets accounting

Module MM
Materials administrationn

Module CO/IM
Controlling und investment management

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Integration with the FI module

Asset number

Financial accounting
Assets Real accounts
Real accounts bookings

PM Objects

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Integration with the CO module poviding cost center Time confirmation

Planning the rates for internal activity using activity types

Actual costs

Rates (in-plant hourly rates)

PM Order

Billing object Cost center or asset Assets account Other order PSP Element

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Integration with the MM module Inventory management

Ordering

Order request for external service or material

PM Order

Goods receipt

Purchase commitments

Invoice receipt
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Invoice

Master data in maintenance

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Installation structure
Functional location
Installation location of a technical object

Equipment
An individual, physical unit installed at a functional location, which requires individual maintenance

Assembly
(Stock) material, which can be used as a structural element in a system

Bill of material (BOM)

A BOM gives structure to a functional location, equipment or an assembly as seen by maintenance

Classes/ Attributes
With the help of classes/attributes freely defined data can be associated with functional locations and equipment
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Structuring / Hierarchy
Functional location

Equipment

Assembly

Spare part
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Anlagenstruktur
Funct.location Funct.location Hierarchy Funct.location Insatalled Equipment Equipment Hierarchy Equipment Equipment/ FL BOM Assembly Assembly BOM

Equipment

Spare part
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Functional location
Definition

An element in a technical structure = assets area at which equipment can be installed

individual maintenance history hierarchical setup classifiable bills of material Order processing
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Functional location
Usage

Arrangement of functional locations by

functional criteria (press, die...) process-oriented criteria (condensation...) spacial criteria (buildings...)

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Functional location
Data transfer

Functional locations
Structuring data Planning data Location data Allocation data

hierarchical Data transfer

subordinate func. locations

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zugeordnete Equipments

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Equipment
Definition

An individual, physical unit which requires its own maintenance.

individual maintenance history
classifiable

Set up at a functional location BOMs / task schedules scheduled maintenance possible Basis fr Instandhaltungsauftrge EMPRISE 05/06
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Equipment
Examples

Equipment = an independent maintainable technical asset

Plant components (pumps, motors, compressors...) Production resources (cranes, tools...) Vehicles

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Equipment
Usage

Planning future maintenance activities Proof of completed PM activities individual cost monitoring technical history of objects Proof of spare parts
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PM assembly

represents a type of device is not tracked separately uses BOMs to sort equipment according to design aspects can also be a storage part can be used to more-closely specify the following PM notifications PM orders Task lists Maintenance plans
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Bill of materials (BOMs)

Structuring
A BOM gives equipment a structure from a maintenance viewpoint

Equipment

Spare part

Assembly

Assembly .....

Assembly

Spare part

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Spare part
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Bills of materials (BOMs)

Mapping to maintenance objects

Equipment 123 Funct. location 1-XX

Equipment BOM Funct. location BOM

Equipment 123 Equipment 133 Equipment 312

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Material 3711

Material BOM

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Classifying PM Objectives: Additional technical information on objects Grupping of objects (functional locations, equipment, material etc.) Searching for objects Analyses of objects

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Measuring point / Counter

Definition
Measuring point
Physical or logical place, defined in connection with a piece of equipment, at which a condition is defined

Counters
The means used to express the usage of an object, the consumption or depletion of a resource

Measurement record
Record that contain the measurements and counter values of measuring points and counters

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Work centers
Work center Basic data Description of the person responsible for the work center Location Usage plan (only for PM task list) Control keys Pattern keys (to describe operations) Capacity type (person/maschine) Capacity (BEB presently, pool capacity) Cost center Activity type

Suggested values

Capacity data

Allocation data

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Maintenance Processing

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Overview PM
Functional flow
Notification Techn. object Direct creation of an order PM Order Planning / Release / Print technical completion confirmation Completion confirmation Completion / settlement
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Maintenance plan

Order processing
Material own / external Activity own / external

History
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Notification

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PM Notification
Notification types

Malfunction Report Describes the condition of an object, especially a malfunction Activity Report Describes an already-completed PM activity. This is a purely technical documentation Maintenance Request Requests a maintenance activity or measure
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PM Notification
Design of a PM notification Description (long text) date/time/reported by Notification PM objekt: Funct.Location Equipment Assembly Notification items Location of damage Damage Cause of damage Activity Auzsfhrungsfaktoren Schedule Task description
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Actions Tasks
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PM Notifications
PM Catalog

Catalogs
Cause of damage Damage Activity

Setup of a catalog catalog

code group

Catalog example
damage catalog: C ALLG (gen. Code Damages) 1000 Break

code
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1100 Fire 1200 Corrosion 1300 Erosion 1400 Cavities

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Maintenance Orders

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PM Order
Functional Flow
Maintenence plan creation release execution Materials management Completion confirmation Internal cost allocation Completion Order settlement
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PM Notification Material planning Capacity planning Purchase

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PM Order
Creation of a PM Order
Creation of an order based on a notification Automatic generation of a PM order from maintenance item Collection of PM notifications into a PM order Direct order creation

PM Notification

Maintenance item

PM Notification

PM Order

PM Order

PM Order

PM Order

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PM Order
Allocation
Functional location/ Equipment Default Rule

Order
Accounting data
Cost center Attachment Special tasks can call for a change in the allocation rules !

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Task Lists

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Task List Usage

Types
- Equipment-specific task lists - PM instructions (equipment-neutral)

Usage
- Recurrent activities - Standardisation of work processes - Plan maintenance steps effectively - Assignment in maintenance plans - Process PM orders in a timely manner

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Task List Structure

Task list header

Equipment Planner group/ Planner group counter Maintenance strategy Internal activity Default values Work center involved Control data External activity Directory of services Supplier Delivery time Purchase data

Work item

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Maintenance Planning

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Maintenance Planning
Definition of a Maintenance Strategy Strategies contain general scheduling rules for preventive PM tasks, which can be assigned to several maintenance plans . In order to map the different maintenance intervals a so-called maintenance package is assigned to a strategy.

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Maintenance Planning
Maintenance Plan types time-dependent maintenance plan
based on a maintenance strategy due to time intervals

activity-dependent maintenance plan

based on a maintenance strategy due to time intervals

Multiple counter plan

no maintenance strategy Cycles are defined in the maintenance plan and if needed they are mapped to counters Cycles can be combined with: OR : at the earliest occurrence EMPRISE 05/06 AND: at the latest occurrence

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Maintenance Planning
Elemente der Wartungsplanung Maintenance strategy
Maintenance strategy Maint. packages time-dependent activity-dependent

Maintenance plan
Maint. scheduling plan

Maintenance order

Maint. items

Maint. orders Objects Functional locations Equipment Operations Equipment plans PM instructions

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Analyses

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History
PM History Database

Maintenance History
Assignment history Order history Notification history

Master records
Equipment functional location

PM order
J Costs J Material J Int. operations

PM notification
J Damages J Causes J Activities

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History
PM History aggregation levels

Aggregate using key figures

PMIS

Aggregate using dif. criteria

List processing

Individual documents

equipment, notifications, orders..

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Contact information
P&S Consulting GmbH Am Kiekenbusch 10 47269 Duisburg Frank Ostwald Director Marketing & Sales 0203-75 99 0-29 Frank.ostwald@ps-consulting.de www.ps-consulting.de

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