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Process Excellence

SAP PLANT MAINTENANCE

Your Trusted IT Partner

SAP R/3 ERP Click to 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)

SAP Organizational Structure Click to edit Master title style

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

Plant Maintenance Introduction Click to edit Master title style 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 Process Flow Click to edit Master title style

Plant Maintenance Process Flow Click to edit Master title style

PM Process Flow

Notification

Maintenance Order

Plan Control

Schedule
Execute Complete

Plant Maintenance Process Overview Click to edit Master title style

Plant Maintenance Organization Click to edit Master title style 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

Plant Maintenance Organization Click to edit Master title style Plant Maintenance Organization
Master Data Characteristics Classes Cost Records Cost Center Tasks List Equipment/Functi onal Locations Maintenance Work Centers Maintenance Strategies Bill of Material

Planning Maintenance Notifications Maintenance Plans

Order Processing Material Reservation

Maintenance Order Capacity Load

Purchase Requisition

Material Issue

Time Conformation

Purchase Order /Release Order

Goods Receipt/Invoice Receipt

Plant Maintenance Organization Click to edit Master title style 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)

Plant Maintenance Organization Click to edit Master title style 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

Plant Based Organization Structure Click to edit Master title style Plant Based Organizational Structure

Plant Maintenance Organization Click to edit Master title style 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.

Plant Maintenance Organization Click to edit Master title style Maintenance Planning Plant Structure

Plant Maintenance Organization Click to edit Master title style 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 Centers Click 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 Centers Click 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

Technical Click toObjects 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,.

Functional Location Creation Click to edit Master title style

Functional Structure Click to Location edit Master title style

Functional Locations

Functional Structure Click to Location 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.

Functional Location Click to edit Master title style 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 Structure Click to Location 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 Equipment Click to 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 areaspecific 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 BOMs 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 Maintenance Click Down to edit 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 Maintenance Click Down to edit 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 Maintenance Click to edit Master title style Break Down Maintenance Flow

Break Down Maintenance

Break Maintenance Click Down to edit 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 Parts Click to edit Master title 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 Process Click to edit Master title style

Break Down Maintenance

Refurbishment Of Spare Parts Click to edit Master title 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 Parts Click to edit Master title 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 Management ClickClearance 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 Management Click to edit Master title style

WCM Process Flow (1)

Order

Create Order

Work Clearance Application

Plan Order/ Request Tag Out

Work Clearance Document

Break Down Maintenance

Work Clearance Document

Specify Object containing Tag out/Lockout Approve and Perform Tag out/Lockout

Work Management ClickClearance 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 Management Click to edit Master title style

WCM Process Flow (2)

Release Order

Release Order Determined Completing Tagging

Work Clearance Application

Work Clearance Document

Perform Un-tagging

Break Down Maintenance

Order Completion

Technically Completing Order

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