SAP - Plant Maintenance Overview - Sourabh

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. 2.

Introduction about PM 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 Accenture AllAll Rights Reserved. 2010 Accenture Rights 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 Accenture AllAll Rights Reserved. 2010 Accenture Rights Reserved.
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
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.
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.
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
7
Technical Objects
= Functional location = Equipment = Bill of materials = Material

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.

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.
Movements of an equipment
Functional Location
Functional Location
Functional Location
Equipment
Equipment
Equipment

Equipment vs. functional location
Technical object
Functional location
Equipment
This is relatively stable, may not be changed in years
This is laid into a certain position and it can be changed more often
Example
Turbine
Motor
Oil pump Shaft

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.
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 BOMs.
Specifies only maintenance relevant components.

Maintenance BOMs 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.
Bill of material structure

Equipment
BOM Header
Text Data Quantity Data Administrative Data General Data
Functional Location
Material
BOM Item
Item Category Item Status Purchasing Data
Sub-Item

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.

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

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.
Classification classes and characteristics
Description
Example Pump capacity, Pressure
Method 1. Create characteristics
Characteristics describing an object
An attribute
Class
A group of objects Pumps, Electric that has the same or motors similar properties
2. Create a class
Object
A classifiable unit
Equipment, Functional location

Pump capacity: 2000
3. Link the class to an object
Characteristics Acceptable values of l/s, Pressure: 1,6 a characteristic value MPa
4. Assign values for characteristics

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.

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.

Catalogue structure
Catalogues for:
Object Part part Damage Malfunction Causes Activities Action Task
Catalogue Structure:
Example :
Malfunction Catalogue Mechanical Malfunction Code 010 020 030 . . .
Catalogue
CodeCode Group group Code Code
Corrosion Broken Glass Defect Engine . . .

Corrective Maintenance Corrective Maintenance process process
23
Corrective maintenance process

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.

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

Standard Maintenance Cycle Data objects
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.
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.
29
Maintenance Order Structure

Elements of Maintenance Order
For example: Order Type, Dates,Plant, Main object, Priority, Description, Maintenance Activity type
Order header
Object list Operation
For example:- Functional Locations, Equipment Maintenance Notifications, Assemblies. For example: Work Centre, Control key, Descriptions Standard time, Activity type,
Material list For example: Material, Quantity, Storage Location

Production resources/tools Settlement Rule Costs (Estimated / Planned / Actual)
Maintenance Order in SAP
31
Notification vs. PM work order
Notification
Technical object Classes
damage cause
Work order
Object list Operations
work center material quantity resources
Activity history No costs
Settlement rules Costs

estimated
planned actual
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.

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.
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.

Stock material process flow
Component assignment Availability check Material reservation Order release Printing Automatic availability check
Goods issue

Non-stock material process flow
Component assignment Purchase application Purchase order Goods receipt
Invoice receipt

PM work order release
Effects of order release:
Reservation effective, can be withdrawn Papers can be printed Confirmation possible Goods movement possible

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.

Technical order confirmation

Before the work order can be completed: Time must be confirmed Activity reports completed
Goods movement reported

Measurement readings recorded
0013456998

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

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

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

Preventive Maintenance Preventive Maintenance
44
Master Data in Preventive Master Data in Preventive Maintenance Maintenance
45
Master data objects
Plant specific master data objects:

Task list Maintenance item Measuring point
Global master data objects:

Maintenance strategy Maintenance plan

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
EQUIPMENT
LABOUR
MATERIALS
47
Maintenance task list structure

Task list Task list header header Operation Operation Sub-operation Sub-operation
e.g. strategy, Task List planner e.g. strategies, maintenance planner group, main work center group, work center, equipment e.g. work center, description, time e.g. work center, description, timing, control key, external processing data, control key e.g. external service maintenance packages e.g. operation, time, work center, description, control key e.g. Material Numbers quantities, BOM items, e.g. quantities, BOM items, unit of measure item category, unit of measure
Material Material
Production Production resources/tools resources/tools Maintenance Maintenance package package
e.g. Mobile Crane e.g. amount, type
e.g. Frequency
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
Preventive maintenance plan
PLAN: Started on date ITEM 1 WO Header info Some parametres Frequency set 1m 3m 6m "Maintenance strategy" A Tasklist: A check calibrate tune replace valve 1a 3a
x x x x
ITEM 2 WO Header info
Tasklist lubricate balance
x x

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).
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.

Preventive Maintenance Process Preventive Maintenance process
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.

Preventive maintenance planning framework

1M * 1000 H 2M * 8000 H 3M * 10000 H etc.
Strategy
Package
Counter *
Maintenance Plan
Object List
Maintenance Item
Call Object /Work Order
Task List
Sub Operation Material Master
Operation
Vendor /Contract Standard Text
Service Master

Refurbishment Process Refurbishment process
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.

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.

Questions?

Any Questions?
Thank you

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SAP Plant Maintenance Module Overview

Presented by Sourabh Sharma

Introduction about PM Structure of Organization with a view to PM

Type of maintenance Corrective maintenance

Introduction to Plant Maintenance

Activities under Plant Maintenance :

Repair / Breakdown Maintenance

Planning Organization Structuring

Decentralized Maintenance Planning

Partially Centralized Maintenance Planning

Maintenance Planning Plant

Master data objects

Plant specific master data objects:

Global master data objects:

7 | 21 Oct, 2004 | oSAP Program

= Functional location = Equipment = Bill of materials = Material

8 | 21 Oct, 2004 | oSAP Program

9 | 21 Oct, 2004 | oSAP Program

11 | 21 Oct, 2004 | oSAP Program

Equipment vs. functional location

This is relatively stable, may not be changed in years

12 | 21 Oct, 2004 | oSAP Program

Specifies only maintenance relevant components.

Assignment of spare parts

Bill of material structure

15 | 21 Oct, 2004 | oSAP Program

Bill of material design

16 | 21 Oct, 2004 | oSAP Program

Document and links

Offers document references and an easy access to related documents for

17 | 21 Oct, 2004 | oSAP Program

Maintenance relevant materials are for example:

Classification classes and characteristics

Example Pump capacity, Pressure

Method 1. Create characteristics

Characteristics describing an object

Equipment, Functional location

3. Link the class to an object

Characteristics Acceptable values of l/s, Pressure: 1,6 a characteristic value MPa

4. Assign values for characteristics

19 | 21 Oct, 2004 | oSAP Program

20 | 21 Oct, 2004 | oSAP Program

Standardized codes enable benchmarking.

21 | 21 Oct, 2004 | oSAP Program

Corrosion Broken Glass Defect Engine . . .

22 | 21 Oct, 2004 | oSAP Program

Corrective Maintenance Corrective Maintenance process process

Corrective maintenance process

24 | 21 Oct, 2004 | oSAP Program

Description of the process

The corrective maintenance planning process

25 | 21 Oct, 2004 | oSAP Program

Notification life cycle

Postpone/ cancel/ continue

Notification is created to report a fault or request for maintenance

Notification in the system can be reviewed and updated

Once the notification is put in process it can be assign to a work order

26 | 21 Oct, 2004 | oSAP Program

Standard Maintenance Cycle Data objects

Monitor the execution of tasks.

Information from the Maint. Order

Where the costs of the order would be settled.