Plant and Machine Maintenance The time has changed, machine breakdown and idle repair is no more accepted

practice. The plant maintenance module in SAP ERP provides an integrated solution for supporting the operational efficiency. The plant maintenance module covers all equipment / machines of the plant. The major sub-system of plant maintenance module in SAP ERP comprises of: Preventive Maintenance Control Equipment Tracking Component Tracking Repair and spare parts maintenance warranty claim tracking. The plant maintenance module in SAP ERP provides an integrated business reports. This reports help you to reduce the duration and cost of downtime. All maintenance tasks such as inspection, servicing and repair activities are saved in a historical database. Plant and Machine Maintenance Module in SAP ERP captures information of equipment maintenance, breakdown analysis. Maintenance module in sap lets you schedule maintenance task calendar for all equipments.
Breakdown Repair Log, Equipment Master Register, Machine Breakdown Log, Maintenance Type, Man Power For Machine Details, Preventive Maintenance Record, Spare Part Installation Log,

Plant Maintenance (PM) Overview of Plant Maintenance (PM) Equipment and Technical Objects (PM-EQM) Preventive Maintenance (PM-PRM) Work Clearance Management (PM-WCM) Warranty Claim Processing (LO-WTY) Plant Maintenance Projects (PM-PRO) Cross-Application Time Sheet (CATS)

Benefits to the client on implementing SAP PM module 1. The equipment history is ON-LINE. You can access information from any of the client locations at any point of time, hence this reduces the time to get information and reduces the time to make a decision for any critical situation 2. All maintenance activities are online, like maintenance plans for the entire year, entire equipments of entire organization, 3. you can track the break down maintenance at any point of time easily.

4. The cost involved for the maintenace acitvites are available online, so no need of any MIS reports at every month. 5. Good integration with Materials for reciveing the material for the maintenance activities from stores. 6. You can maintian the equipment / loctation BOM in the system, which enables you to view the BOM easily at any point of time. 7. Easy tracking of malfuntioning, breakdown and procee down maintenance activites. 8. You can maintian the equipmet log sheet online. like boiler temp reading etc.... 9. You can integrae with Qulaity module and monitor calibration maintenance. 10. You can have permits online instead of having on paper and roaming to the depts to get the permit. 11. Over all your information about the maintenance is online and you can maintian paper less environmnt.

Preventative Maintenance

The SAP PM module is able to plan and manage scheduled, proactive, maintenance procedures designed to prevent, or predict, breakdowns to critical systems, which can be costly not only in terms of repair, but also in terms of lost production. In difficult, demanding industries, such as the oil production industry, the SAP PM module can increase the availability of the multitude of pumps, valves and other equipment that constitute an oil drilling platform.

Problem Rectification

The SAP PM module also allows maintenance organizations to identify and rectify problems with any of the equipment under their control, whether theyre cause by complete failure or deterioration over time. The SAP PM module automatically pinpoints the exact location of faulty equipment and generates a detailed maintenance order, including any necessary specifications, engineering drawings and safety precautions. All of these details are critically important because if any of them are missing maintenance may not be possible, potentially halting production or endangering lives or both.

Split-level

Maintenance

One of the major benefits of the SAP PM module is that it allows plant maintenance to be broken down into various levels, at both the planning and performance stages. The SAP PM module obviously permits individual, independent equipment, such as vehicles, to be maintained independently, but also permits other types of equipment, such as a production line -- which consist of several pieces of interdependent equipment -- to be maintained as a functional location, rather than a collection of independent components.

Other Benefits

Overall, the SAP PM module allows plant maintenance businesses and functions to be standardized across an organization and integrated with other functions. In so doing, it

reduces reliance on paper-based systems or standalone computer systems. Furthermore, the SAP module creates structured information -- with regard to the cost and technical history of critical systems -- which affords better control of resources, manpower and overall maintenance costs. The SAP PM module also serves to promote the ownership of maintenance data among its users, as well as the monitoring and improvement of performance measures as far as plant maintenance is concerned.

SAP PM Benefits
Reduce your plant maintenance and operating costs! Properly maintain your machines to minimize downtime. Your production costs decrease! Reduce your long-term maintenance operating costs! Minimize your breakdowns and emergency repairs. Minimize your emergency expenditures. Lower your cost for parts purchased. Lower your inventory holding costs.

Reduce your outside contractor costs since the maintenance department has more time for preventative maintenance procedures. An overall reduction in your maintenance operation cost due to organization and efficiency. Better planning of your jobs! Get them done correctly the first time and in a timely manner with minimal call backs. Improve Your Quality: Consistent operation of your machinery improves product quality. Setup and operation of your equipment is more accurate. Reduce Your Waste: With proper maintenance, your machines can operate without stoppage to reduce waste in your facility. Reduce Your Energy Consumption: Correctly maintaining your machinery uses less energy. Extend Your Equipment Life: Reduction in capital spending when your equipment lasts longer due to correct and timely preventive maintenance. Employee Training: A good PM system database (procedures and tasks) acts as an employee training system. The detailed tasks explain exactly how to perform repetitive maintenance. Your new employees will no longer need to guess how to do things in your department.

Reduce Your Employee Turnover: Minimize breakdowns and improve employee morale by allowing them to take pride in the job they are doing. Empower your employees by giving them modern tools to accomplish everyday tasks. Management expresses interest by providing your department with the proper tools to get the job done (SAP PM software is a tool for the maintenance department). Reduce job stress with minimal breakdown and emergency repairs! Improve the Safety of Your Employees and Equipment: Machine safety increases with machine reliability. A PM system can include safe work procedures and safety checks of critical components in order to keep your mechanics and operators safe. Your Additional Cost Reductions: Cost reductions come in many ways as secondary benefits of a CMMS system. Worker efficiency increases since they go to a job with the correct parts and instructions. Machines require less parts and repairs when correctly maintained. Prices paid per part are less due to known prices previously paid. Vendors are unable to indiscriminately raise prices (It is not uncommon for a medium-sized plant to have 5 to 10 thousand different purchased parts. How do you keep track of this type of information without a good inventory system?). Purchaser of parts is more efficient due to available information (Where part is purchased, last price, vendor, quantity used since last purchase, other vendor prices). Purchaser can spend more time researching lower prices to save on part prices. What can you actually expect to gain by implementation? Actual surveys* have shown a 10%20% reduction in maintenance labor costs and a 10%15% reduction in parts cost. *(Thomas Marketing Information Center) Justification for purchasing a system is adequate on these reductions alone. The largest cost savings comes from improved efficiency of your plant, quality improvement of the product and all the other benefits previously discussed.

sap pm Benefits
Reduce your plant maintenance and operating costs with SAP PM benefits! With the SAP PM benefits you can properly maintain your machines to minimize downtime. Maintenance costs decrease and even your production costs decrease! Fewer stoppages of your operation means more efficient use of equipment, raw materials are not wasted due to breakdowns, and your planned schedules are met quickly and effectively with CMMS benefits. Imagine production costs going down. Hard to believe maybe, but why not? If the benefits to your operation are an increase in the efficient use of all labor and materials, you will reduce operating costs. That can and will be the result of your SAP PMbenefits to your all-around maintenance management. CMMS also reduces your waste. Imagine how with proper maintenance, your machines can operate without stoppage and how that alone can help reduce waste in your facility. The list goes on and on with the features of COGZ CMMS. You also reduce your long-term maintenance operating costs with SAP PMbenefits! How? By minimizing your breakdowns and emergency repairs and at the same time lowering emergency expenditures, your costs are lower for purchased parts; hence, inventory-holding costs are lower. Parts and components have a longer life span. Every operation has materials and parts that are just expended because of how they need to be abused. You just write them off because so far, there is no better way. Just think, longer life for them means reduced costs, usually in both labor and materials.

Another benefit is you can reduce your outside contractor costs with CMMS since the maintenance department has more time for preventative maintenance procedures. Many preventative maintenance tasks that are now done by contractors can now be completed in-house. With COGZ in place, this is easily accomplished. When repair technicians have to do nothing but answer relentless breakdown calls, their work performance will drop. Yet when breakdowns are lessened and more of their work is properly planned, their interest can grow. They may even become integral forces for the success of your CMMS. So the bottom line is, with the numerous benefits of COGZ CMMS, you can expect an overall reduction in your maintenance operation cost due to organization and efficiency of the CMMS. By better planning of your jobs, SAP PMhelps you get them done correctly the first time and in a timely manner with minimal call backs. Could there be even more benefits to COGZ CMMS? Absolutely! What about improving your quality? With COGZ, the consistent operation of your machinery will improve product quality. The setup and operation of your equipment is more accurate resulting in less equipment startup failures with your preventive maintenance system properly in place and utilized effortlessly with your entire maintenance team. Try your free evaluation version of COGZ today and see how the benefits can be an asset to your entire facility maintenance management SAP routine!

Every Type of Maintenance Operation - Around the World!

Facility Industrial Associations Property Maintenance Manufacturing Plant Distribution Hospitality Warehousing Hotels Military Electronics Processing Power Generation Educational Facilities Truck Construction Fleet/Vehicle

Colleges/Universities Schools Medical Laboratories Research Public Works Technology

Food Processing Plants Oil/Gas Government Transportation Automotive Utilities

Overall, a reduction in the departmental maintenance budget of between 5% and 15% can be reasonably expected. Most vendors sell their packages using some or all of the following benefits. If all breakdown statistics are collected for the first few months then the areas where preventative maintenance is required will become self-evident. Failure trends will also be self-evident and corrective actions can be identified. If your computerized maintenance management software has a suitable report generator this will make the generation of effective maintenance statistics a speedy, simple task

Badly Managed Maintenance Problems

Maintenance is heavily dependent on skilled and specialized trades persons No records are kept and much of the equipment history is inside people's heads It is impossible to estimate maintenance costs High levels of maintenance related overtime are being worked

Maintenance is perceived by management as a necessary evil The greater amount of maintenance man-hours is spent on unplanned work as opposed to preventive maintenance or planned maintenance inspections.

Benefits of Well Managed Maintenance

Management recognize maintenance as an integrated, essential part of production Maintenance focus is on making equipment available through increased reliability There is an emphasis on analysis of the reasons for down time There is a commitment to planned work There is an emphasis on training Continuous improvement programs are in place Operators are involved in the maintenance of their equipment.