breaking through barriers to progress

Plant Maintenance in SAP A functional perspective

By Gopinath

an award winning '2004 Future 50 Company' 18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.0200

SAP R/3 - Overview

Overview: R/3 Overview and Integration

TeamSAP Academy R/3 Overview & Integration

Getting Started
SD
Sales Sales & Distribution

R/3 Applications
FI
Financial Accounting

MM
Materials Materials PP Mgmt Production Planning Planning

CO
Controlling

AM

R/3
IS
Industry Solutions

Asset Mgmt Mgmt

PS Client / Server Project Quality System Mgmt ABAP PM WF QM

Plant Plant Maintenance Workflow

HR

Human Resources

Support & Services System-Wide Concepts

SAP AG

Plant Maintenance - Overview

SAP R/3 Modules

Logistics
MM PP
Production Planning

SD
Sales & Distrib. Distrib. Material Manag. Manag.

FI
Financial Accounting

Accounting
TR
Treasury

CO
Controlling

R/3
Client / Server ABAP
HR IS
Industry Solutions

QM
Quality Manag. Manag.

PS
Project System

PM
Plant Maint. Maint.

WF
Workflow

Human Resources.

Human Resources

Cross Application Functions

R

SAP AG

Plant Maintenance - Overview

What Is Integration?
Common organizational structures throughout the system Seamless processing of common data between applications Comprehensive support and reference tools Common reporting features and functionality

SD MM PP QA PM HR

FI CO AM PS WF

R/3
IS

Object and application linking and overall system communication

SAP AG

Plant Maintenance - Overview

Organization of Plant Maintenance: Business Scenario

Plant Maintenance is an integral part of the company and has numerous links to other enterprise areas. Depending on the company structure, maintenance planning is either plantbased (decentralized) or cross-plant (centralized).

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Plant Maintenance - Overview

Structure of Plant Maintenance
EQM Technical Data
Functional locations Equipment Assemblies Bills of material Networks of technical objects

PRM Preventive Maintenance

Task lists Maintenance plans

WOC Maintenance Processing

Maintenance notifications Maintenance orders

PMIS Plant Maintenance Information System CRP Work Centers and Capacity
Maintenance work centers
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Plant Maintenance - Overview

Concept of Plant Maintenance

Master data
Characteristics Classes Cost records Cost center Maintenance work centers Bills of material Task lists Maintenance strategies

Equipment / functional locations

Planning
Maintenance notification Maintenance plans

Order processing
Material reservation Material issues
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Maintenance order Capacity load Time confirmation Purchase requisition Purchase orders / release order Goods receipt / invoice receipt

Plant Maintenance - Overview

Organizational Structures in Plant Maintenance
General Organizational Units in Logistics Client Company code Plant Location-Based Organizational Units Maintenance plant Location Plant section Planning-Based Organizational Units Maintenance planning plant Maintenance planner groups Maintenance work centers
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For example, site, building, coordinate For example, production area, plant engineer

For example, foreman, work scheduling For example, mechanics

Plant Maintenance - Overview

Cross-Plant Maintenance

Plant 1200 Maintenance requirement

Plant 1300 Maintenance requirement Workshops

Plant 1000 Planning of maintenance requirements Maintenance requirement

Warehouse

Workshops Material
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Plant Maintenance - Overview

Maintenance Work Centers

Maintenance work centers For example: Welding Metalworking Mechanics

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Plant Maintenance - Overview

Work Center: Contents

Basic data
General data

Capacity data
Capacity categories Scheduling

Capacity / pool capacity

Available capacity profile

Links

Activity types Activity types Activity types Cost center Work center Person Staffing assignment Staffing assignment Qualification Staffing assignment

Time

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Plant Maintenance - Overview

Work Center: Main Functions
Work Work Center Center
11

10
Default Default values values for for task task lists lists and and orders orders Costing Costing data data

Scheduling Scheduling data data and and available available capacity capacity

Task Task list list // order order

Costing Costing

Lead Lead time time scheduling scheduling Capacity Capacity planning planning

2,724.00 2,724.00 1,200.00 1,200.00 124.00 124.00 4,048.00 4,048.00

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Plant Maintenance - Overview

Functional Location
Functional location = multi-level, hierarchical structure, organized according to ...

Spatial

Technical

Functional

Criteria
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Plant Maintenance - Overview

Criteria for Functional Locations

When is a functional location created?

Execution of maintenance tasks Recording of maintenance tasks Data collection over long periods of time Cost monitoring by area What effect do the usage conditions have on the likelihood of damage to the installed aggregates?

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Plant Maintenance - Overview

Automatic Assignment Upon Creation

Existing functional locations

C1 Clarification plant
C1-M Mechanical cleaning C1-B Biological cleaning

C1-M01 Sand trap

C1-M02 Oil/fat trap

C1-B01 Pump plant

C1-B02 Filtering station

New functional locations

C1-M01-2 C1-M01-2 Ventilator Ventilator

C1-M02-2 Ventilator

C1-B01-1 Pump 1

C1-B02-2 Filter cell

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Plant Maintenance - Overview

Example of Functional Location Structure
C1 Clarification plant
C1-M Mechanical cleaning C1-B Biological cleaning

C1-M01 Sand trap

C1-M02 Oil/fat trap

C1-B01 Pump plant

C1-B02 Filtering station

C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3 Sand Fat Reservoir Ventilator dredger Reservoir Ventilator dredger

C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2 Filter cell Pump 1 Pump 2 Ventilator

C1-B02-1A C1-B02-1B C1-B02-2A C1-B02-2B C1-B02-2C Filtrate Valve 1 Valve 2 Inlet level Outlet

C1-B02-2A/1 C1-B02-2A/2 Valve 1 Valve 2

C1-B02-2C/1 C1-B02-2C/2 Valve 1 Valve 2

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Plant Maintenance - Overview

Criteria for Equipment Master Record

When is a piece of equipment created?

Management of individual data Recording of maintenance tasks Object-based recording of costs Evaluation of technical data Recording of usage times

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Plant Maintenance - Overview

Equipment Master Record
Location A

Equipment Equipment master master record record

Equipment usage Classification

Location B

List X X X X X X X

General General Location Location

Documents / technical drawings Multilingual texts

Organization Organization Structure

Address / partner Measuring points / counters Permits Internal note

0471 0123

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Plant Maintenance - Overview

Bills of Material in Company

Production bill of material

Engineering/design bill of material

Maintenance bill of material

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Costing bill of material

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Plant Maintenance - Overview

Breakdown Maintenance: Business Scenario

For breakdown maintenance, the data required for the other business processes needs to entered quickly and easily so that the subsequent steps can be executed.

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Plant Maintenance - Overview

Business Process: Breakdown Maintenance

1 2
3 4 5 2 3

Notification

Technical object Description

Date Malfunction

Planning Scheduling
Execution Execution

Work to be performed Material Internal/external resources Tools

Order release Printout

Capacity leveling Availability check

Planned/unplanned material withdrawal External procurement

Completion

Time confirmation Order settlement Technical completion Technical confirmation

History
Material Material usage, usage, orders, orders, notifications, notifications, PMIS, PMIS, usage usage list list
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Plant Maintenance - Overview

Maintenance Order: Putting in Process

Status 'RELEASED'

Order papers
Put in process

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Plant Maintenance - Overview

Time Confirmations
Initial screen

Individual entry Collective entry Collective entry using operation list Overall completion confirmation Partial confirmation Final confirmation

Scope

Reversal option

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Plant Maintenance - Overview

Maintenance Order: Technical Completion

Order 901760
Limited ability to change order Status 'Technically completed' Define location and account assignment data Create settlement rule Set deletion flag for purchase requisitions Close open reservations Close open capacities

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Plant Maintenance - Overview

Cycle for Corrective Maintenance

1 2 3 4 5

Notification Planning Scheduling Execution Completion

Technical object Description

Date Malfunction

Work to be performed Material Internal/external resources Tools

Order release Printout

Capacity leveling Availability check

Planned/unplanned material withdrawal External procurement

Time confirmation Order settlement Technical completion Technical confirmation

History
Material usage, orders, notifications, PMIS, usage list
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Plant Maintenance - Overview

Definition of Maintenance Notification
Describes the condition of a maintenance object, particularly a malfunction Malfunction report

Describes a maintenance activity already performed (purely technical documentation) Activity report

Requests a maintenance service/task

Maintenance request

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Plant Maintenance - Overview

Maintenance Notification: Structure
Date / time / reported by Description Object: Functional location Equipment Assembly Material serial number Location data Breakdown / availability Notification Text items Damage location Damage Cause of damage

Notification

Activities

Activity Execution factors

Tasks

Dates Task description

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Plant Maintenance - Overview

Maintenance Notification: Object Information

Orders Maintenance dates Notifications

Documents

Processing days

Object information Structure list

Links Breakdowns

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Plant Maintenance - Overview

Select Maintenance Notifications
Why ? Find particular maintenance notification Process several maintenance notifications simultaneously Restrict planning worklist Scope Notification Notification items Tasks Customizing Selection conditions Field selection Functions Different sorting Select / delete complete list Different list fields, internal display variant Display breakdowns graphically Excel processing
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Plant Maintenance - Overview

Print Maintenance Notifications

Maintenance notification

Fax transfer

Notification overview Breakdown report

Activity report

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Plant Maintenance - Overview

Cycle for Corrective Maintenance

1 2 3 4 5

Notification
Planning

Technical object Description

Date Malfunction

Work to be performed Internal/external resources

Material Tools

Scheduling Execution Completion

Order release Printout

Capacity leveling Availability check

Planned/unplanned material withdrawal External procurement

Time confirmation Order settlement Technical completion Technical confirmation

History
Material usage, orders, notifications, PMIS, usage list
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Plant Maintenance - Overview

Creation of Maintenance Orders
Direct creation of order Creation of order based on notification

Maintenance order / notification

Maintenance notification Maintenance notification Maintenance notification Maintenance notification Maintenance order Maintenance item

Maintenance order

Combination of maintenance notifications for maintenance order

Maintenance order

Entry of order with subsequent activity report Automatic generation of maintenance order from maintenance item
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Maintenance notification Maintenance order

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Plant Maintenance - Overview

Characteristics of Maintenance Orders

Flexibility of order processing

Object reference Single object Object list Period of validity Single order Standing order Execution Internal processing External processing

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Plant Maintenance - Overview

Stock Material - Process Flow

Component assignment Material reservation Order release

Availability May check

Printing Automatic availability check May

Goods issue

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Plant Maintenance - Overview

Cycle for Corrective Maintenance

1 2
3

Notification Planning
Scheduling

Technical object Description

Date Malfunction

Work to be performed Material Internal/external resources Tools

Order release Printout

Capacity leveling Availability check

4 5

Execution Completion

Planned/unplanned material withdrawal External procurement

Time confirmation Order settlement Technical completion Technical confirmation

History
Material usage, orders, notifications, PMIS, usage list
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Plant Maintenance - Overview

Resource Planning: Availability Check

Plant stock

Material withdrawal for cost center Stock transfer to other plant Inward stock movement from purchase order Inward stock movement from internal production Maximum ATP quantity Stock profile

Safety stock Today Requirement date

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Plant Maintenance - Overview

Maintenance Order: Printing

Maintenance order
Job ticket

Fax transfer

Material Operation control ticket Pick list Time ticket Object list withdrawal slip Confirmation slip

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Plant Maintenance - Overview

Order Completion Confirmation: Times / Activities

Times
Individual entry Collective entry Overall completion confirmation Time sheet (CATS)

Activities
Activity reports Overall completion confirmation Confirmation texts

Object changes

Measurement readings
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Plant Maintenance - Overview

Questions ??

Contact Details : mail id : gthangavelu@darylflood.com Cell : 469-879-4674 Residence : 972-444-8510

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