02 - SAP PM Plant Maintenance Universal Process Model

SAP PM End Users Training
Plant Maintenance
Universal Process Model (UPM)
Plant Maintenance
Universal Process Model (UPM)
Asset Management Structure

Asset Maintenance Management
Conduct budget control
Perform intercompany spare parts sales
Measuring Point (PM & Fleet)
Project execution for assets
Conduct order managed modifications
Install capital equipment
Dismantle equipment
Preventive / Predictive Maintenance
Perform preventive / predictive maintenance
Corrective maintenance
Conduct unplanned/emergency breakdown maintenance
Perform low cost repairs
Perform Planned Repairs
Refurbish spare parts
Asset Management Processes

Broken up into 4 Core Process Functions

1) Asset Maintenance Management
2) Execute Projects for assets
3) Preventive/Predictive Maintenance
4) Corrective Maintenance
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct Budget Control
Depending on the implementation within the
company, budgetary control measures can be
set up at cost center level or for the
maintenance order itself. At individual
maintenance order level, a budget can be set
and once the budget has been reached, no
more costs can be accumulated against that
order. The budget can be changed with the
necessary authorization

Perform Intercompany Spare Parts Sales -
Within R/3, the stock of spare parts can be
viewed across plants. It is however, important
to ensure that there is standardization
relating to the relevant master data of the
parts.

Measuring Point (PM & Fleet) -
measurement documents are created against
the assets that allow for follow up activities in
invoicing and managing fuel usage against
distance incurred (Fleet)
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Budget
Control
Perform
Interco.
Spares Sales

Measuring
Points
(PM & Fleet)
Conduct Order Managed Modifications -
A modification to equipment is made to
improve its performance or to prolong its
usable life. This is a planned intervention, for
which a cost estimate and approval is
required. This process adds value back to the
asset.

Install Capital Equipment -
Maintenance departments are commonly
used to assist with the installation of Capital
Equipment. This process describes the use of
the Maintenance Order to procure the
equipment and the settle it to WBS elements
and the settlement of the labor to expense
cost elements.

Dismantle Equipment -
Within Capital Projects, an expense portion
can exist in the dismantling or demolition of
the equipment. This process make use of the
Maintenance Order to accomplish. It also
triggers the need for asset disposition and
changes to functional location structures

Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Order Managed
Modifications
Install
Capital
Equipment
Dismantle
Capital
Equipment
Project Execution for Asset
Preventive/Predictive Maintenance
Perform Preventive/Predictive Maintenance

Process allows for the development of
routine and repetitive pre-scheduled
maintenance activities

Support Reliability Principles
Support Operational Excellence
Methodologies
Flexible for PM Optimization
activities
Flexible to institutionalize PMs based
upon COE Successful Practices
Options for Time Based, Performance
Based, and Condition Based PMs
available
Can be set to single cycle, multi-
cycle, or a combination of both
Can be used to manage EOSH routine
activities

Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Preventive/
Predictive
Maintenance
Corrective Maintenance

Processes support both Reactive and Proactive Corrective Maintenance activities:

Perform Emergency Repairs -
o In this process the steps before completion of the work are minimized so efforts go towards resolving
issues associated with the emergency. After completion of the repair, history is then gathered.

Perform Low Cost Repairs -
o In this process, a standing order is created to capture confirmed activities to repair minor stops and
short duration fixes.

Perform Planned Repairs -
o Newly created to enable and institutionalize the COEs best practice Proactive Maintenance Planning
and Scheduling processes

Refurbish Spare Parts w/Split Valuation -
o This process deal with the refurbishment of - usually high value - faulty repairable spares. This is of
considerable economic importance for our bottlers and is often a core process in Plant Maintenance. It
is often much more cost-effective than a brand new purchase.

R
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P
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Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Perform
Emergency
Repairs
Perform
Low Cost
Repairs
Perform
Planned
Repairs
Refurbish
Spare Parts
Asset Management

These 4 Core Process Functions, Asset Maintenance Management, Execute Projects,
Preventive/Predictive Maintenance, & Corrective Maintenance, now provides us the Asset
Visibility to:

1. Reduce Operating Cost by improving Labor utilization
2. Reduce Operating Cost by better managing parts and services
3. Reduce the Asset swell in spare parts by better management locally, regionally, and
globally, bring down unproductive inventory values
4. Reduce spend on spare parts procurement
5. Reduce the need to procure more capital
6. Focus on key Assets that provide the best opportunity to add availability and capacity
without adding capital
7. Increase Efficiencys
8. Increase Throughput
9. Reduce other Supply Chain costs
10. Ultimately improve the Return on Assets involved in the Make Process of Finished
Goods

Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Plant Maintenance
Technical & Object data
& Base Requirements
Required Organizational Entities
10 10
According the Systems Applications and Products (SAP) standard organizational objects, the business
scenario is mapped as follows:

General organization
Location-based organization
Planning-based organization
(i.e. oil &
gas
company)
Company Codes
Company codes generally represent the various legal entities within an organization. The Company Code is
the lowest level for which you can produce a complete set of financial reports.
There is no PM configuration in this area.

Plants
In the Enterprise Resource Planning (ERP) System, the plant is a place of work or a branch within a
company. The plant is integrated in the organizational structure as follows
One plant (i.e. plant -0001) is assigned to exactly one company code (i.e. Company - 1000). One company
code can have several plants.
One plant can have several storage locations at which materials stocks are stored
Exactly one business area is assigned to a plant and a division
A maintenance plant can be defined as a planning plant

A plant has the following attributes:
It has an address.
It has a language.
It belongs to a particular country.
It has its own material master data.
.

11 11
Maintenance plants and planning plants

The maintenance plant of a technical object is
the plant in which the object is installed.

The planning plant of a technical object is the
plant in which the maintenance tasks for that
object are planned and prepared.

Planner groups is part of the planning
plant which prepare a tasks for the
technical object in maintenance plants

12 12
Planner Groups

Planner Groups are also organizational structure units.
This is typically localized, but customization and logic to
other functions such as notification screens and printing
uses standard Planner Groups for PM to provide added
functionality.
The below have been set up in the system to be
maintained .

Planner groups can move to being plant specific because
of segregation from CAM

Work Centers

Work Center (Location Tab) is defined as an
organizational unit that assigns where the technical
object is located.
This is the Production Planner (PP) Work Center and
not the Maintenance Work Center which is usually
associated to labor.
Where possible in Equipment Record and Functional
Location Record this field should be populated. This
require obtaining the PP Work Center information for
populating this information in advance or as a
dependency during load.

13 13
Storage Locations

The Storage Location is defined as an organizational
unit, allowing for differentiating between the
various stocks of a material in a plant.
Specified amounts of materials can be moved
between different storage locations.
A Storage Location is typically represented by a
plant-unique 4-digit alpha-numeric.
Material stocks can be differentiated, on a quantity
basis, within one plant according to storage
location.
Storage locations are always created for a plant.
Physical inventories are carried out at storage
location level.
For Coke One, common storage locations have been
set up for each plant.

Plant Section

Plant Section is generally considered a local
organizational unit. It is used to further breakdown a
Maintenance Plant into physical or logical functions.
Guidance is given in this area as the Plant Section is also
used in the Functional Location structure to provide
consistency in analysis of various plants in the BIG.
There is no straight forward way to standardize this
organizational unit as each plant has its own unique
differences and configuration. The below provides
guidance to selecting the Plant Section number.

010 019 General Plant Services, Building & Grounds
020 029 Bottle /Can Sorting & Delivery Systems
030 039 Blending & Mixing Production & Packaging
040 049 Production & Packaging
050 059 Warehousing and Logistics
060 069 Trade Services
070 079 Fleet
080 089 Office & Support Functions
090 099 Redeployable Asset

14 14
Required Data Elements - Functional Location
The structure indicator of a functional location determines the structure of the functional location label. It
establishes the following factors:
Number of hierarchy levels of a technical system
Key length of the levels
Separators (hyphens)

For Coke One, the Structure Indicator is ZSTD. The edit mask assigned to it is:
NNNN-NNN-NN-NNN-NNNNN

NNNN = Plant Code (i.e., 0000 = Singapores Plant Number) Spatial
NNN = Plant Section (i.e., 010 = Manufacturing Bldg) Spatial and Process-based
NN = Type of Line or Process (i.e., 01 = Production Area) Process-based
NNN = Plant Line # or Plant Process# (i.e., 001 = Line 1) Spatial
NNNNN = Equipment /System Function (i.e., 00100 = Filler) Functional

Example above = 0001-010-01-001-00100

15 15
Perform Preventive Predictive Maintenance -
Master Data

SAP Technical & Object data & base requirement

1. Work Center List Display (CR05)
2. Functional Location Structure Display (IH01)
3. Equipment List Display (IE03)
4. Function location master data Display (IL03)
5. Equipment master data Display
Asset Maintenance
Management
Asset Management
Measuring point (PM & Fleet)
Dismantle equipment
Conduct emergency breakdown maintenance
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Budget
Control
Perform
Interco.
Spares Sales

Measuring
Points
(PM & Fleet)
18
Measuring Points and Counters
A Measuring point is Master Data created for a Technical
Object in order to document a Measurement or a Counter
reading. This is done for one of three reasons:
You want to document the condition of a technical
object at a particular point in time.
You want to perform Counter Based Maintenance
(Preventive).
You want to perform Conditioned Based
Maintenance (Predictive).

In the case of Counter Based Maintenance, maintenance
activities are scheduled to be performed when the Counter of
the Technical Object has reached a particular Counter
Reading, for example, every 100 Operating Hours.

In the case of Condition Based Maintenance, maintenance
activities are scheduled to be performed when the Measuring
Point of a Technical Object has reached a particular state, for
example, every time a brake pad has been worn away to the
minimum thickness permitted, or when the cooling water for
a Nuclear Power Plant exceeds the upper limit allowed.

The Measuring Point must have a Characteristic assigned to
it.

18
Fleet Measuring Point (KM & Fuel Consumption
reading)

Asset
Management
Measuring
Points
(PM & Fleet)
Create Equip
Create
Measuring
Point
Close
Asset
Maintenance
Management
Fleet Measuring Point (KM & Fuel Consumption
reading)

SAP - Processing of Measurement Points process
flow
1. Display equipment master for vehicle w/
Measuring point (IE03)

2. Display & Changes measuring point list (IK32)
i.e. 2000011

3. Reading entry (IK34)

Asset Maintenance
Management
Asset Management
Send fuel card information
Dismantle equipment
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Order Managed
Modifications
Install
Capital
Equipment
Dismantle
Capital
Equipment
Conduct Order Managed Modifications

Asset
Management
Project
Execution
For Assets
Order
Managed
Modifications
Request
for project
modificati
on
Finance
Approval
for WBS
Notificatio
n
approved
Create
order &
release
Confirmati
on
Close order
&
Notification
(TECO)
Finance
settle to
WBS

A modification to equipment & function
location is made to improve its
performance or to prolong its usable
life. This is a planned intervention, for
which a cost estimate and approval is
required. This process adds value back
to the asset.

SAP - Order Managed Modifications process flow
1. Create Project request (IW21)

2. Create CapEx order & release (IW31)

3. Order Confirmation (IW41)

4. Close order & notification (TECO) (IW41)

5. Display WBS (CJ03)
6. WBS Expenses /Budget, Plan & Actual cost report
(S_ALR_87013558)
Install Capital Equipment

Asset
Management
Project
Execution
For Assets
Install
Capital
Equipment

Maintenance departments are
commonly used to assist with the
installation of Capital Equipment.
This process describes the use of
the Maintenance Order to
procure the equipment and the
settle it to WBS elements and the
settlement of the labor to
expense cost elements.
Request
for project
installatio
n
Finance
Approval
for WBS
Notificatio
n
approved
Create
order &
release
Confirmati
on
Close order
&
Notification
(TECO)
Finance
settle to
WBS

SAP Install Capital Equipment process flow

1. Install Capital Equipment (IE02)

Dismantle Equipment

Asset
Management
Project
Execution
For Assets
Dismantle
Equipment
Dismantle Equipment
Within Capital Projects, an expense
portion can exist in the dismantling
or demolition of the equipment.
This process make use of the
Maintenance Order to accomplish.
It also triggers the need for asset
disposition and changes to
functional location structures
within R/3.

Request
for
Dismantle
Finance
Approval
for WBS
Notificatio
n
approved
Create
order &
release
Confirmati
on
Close order
&
Notification
(TECO)
Finance
settle to
WBS
Dismantle Equipment

1. Dismantle Equipment Process (IE02)

SAP Dismantle Equipment process flow

Preventive/
Predictive
Maintenance
Asset Management
Dismantle equipment
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Preventive/
Predictive
Maintenance
Perform Preventive/Predictive Maintenance
29
Preventive
Maintenance
Maintenance Plan
Schedule the Plan
Create PM Orders
Adjust planned
dates if required
Release the Order Execute Maintenance
Maint. Operation
Confirmation
Technically complete
the order
Record technical data
in notification
Complete notification
30 30
Strategy plan
Time-based Performance-based
Maintenance plans
Perform Preventive Predictive Maintenance
Preventive Maintenance Plan: Structure
Maintenance items
Preventive
maintenance plan

Maintenance
Schedule

Maintenance orders

Preventive
Maintenance
strategy
Maintenance
task list
Maintenance items
31
Maintenance
Package

SAP - Preventive maintenance process flow
1. Maintenance Strategy Display (IP12)
2. General Maintenance Task List Display (IA07)
3. Maintenance Plan Display (IP03)
4. Maintenance Plan Scheduling
Display/Reschedule/Manual Call (IP10)
5. Generating and list of orders IP30&IW38
Corrective
Maintenance
Asset Management
Dismantle equipment
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Perform
Emergency
Repairs
Perform
Low Cost
Repairs
Perform
Planned
Repairs
Refurbish
Spare Parts
Conduct Emergency Breakdown Maintenance

Asset
Management
Corrective
Maintenance
Emergency
Breakdown
Maintenance
Break
down
Notification
& Release
Work Order
& Release
Confirm
TECO
Conduct Emergency Breakdown Maintenance

1. Create PM Notification- ZU (IW21)
SAP - Emergency Breakdown process flow
2. Create Order & Release (IW31)
4. TECO (IW32)
37
Perform Low Cost Repairs

Within a limited range, a technician may confirm times, and only times, to
a standing order as long as there is no goods issue involved (no spare parts
consumed).

If a goods issue is involved or the time limit is exceeded, the technician
has to trigger the release process for a notification and order.

The work order is only open for a specified time period

Notifications are created for low cost jobs and linked to the open work
order
Asset
Management
Corrective
Maintenance
Perform
Low Cost
Repairs

Create Standing Work Order (ZP)

Create Notifications (ZU)

Assign Notifications to Standing Work Order

Confirm Notifications

Standing
Order
Low
Effort
Not.
Assign
Not. To
Order
Confirm
Close
Order

Low Cost Repairs Process flow
2. Create PM Notification (Low cost assign to order) (IW21)
1. Create Order & Release Open order, ZP03(IW31)
3. Operation Confirmation (IW41)
5. TECO (After 6M or 1Y) (IW32)
4. Notification close (after job is done) (IW32)
Perform Planned Repairs Process Flow

Asset
Management
Corrective
Maintenance
Perform
Planned
Repairs
Problem
IDd
Notify
Create
WO
Plan
WO
Schedule
WO
Execute
WO
Doc &
Close

SAP - Planned Repairs process flow

1. Create PM Notification- ZP - (IW21)
4. TECO Order & Notification close (IW32)
Refurbish Spare Parts

Bought stock and
put into spares
Special type of
maintenance
order
Broken Item
Broken Item
Asset
Management
Corrective
Maintenance
Refurbish
Spare
Parts

High value materials or spare parts, such as motors, are often used in production systems. In the event of failure
or damage to these types of parts, they may be replaced by a functioning spare, then refurbished in the
maintenance department or externally if deemed more cost effective to do so. Refurbishment is frequently
considered more cost effective and should be applied when this is the case. The cost to process the routine has to
be weighed also, considering planner time, purchaser time, and storeroom attendant time. With this in mind, as a
guideline, spare parts having an individual value of 500 Euros or more (roughly $750) should only be considered
for refurbishment. Only in special cases should other parts be put into the refurbishment process.

In typical corrective maintenance repair processes, some described above, work order are set for the consumption
of materials or parts. In the refurbishment process, work orders are intended to repair the defective part. To
accomplish this, the refurbishable material has to be classified by 3 different states, called valuation types. They
are: New, Refurbished, and Defective. The valuation types have been set up in the system as:

Asset
Management
Corrective
Maintenance
Refurbish
Spare
Parts

SAP - Refurbishment of spare parts process flow

3. TECO Order close (IW32)
Material Masters

The material master contains descriptions of the articles and parts that the plant, manufactures, and
stores. The material master is the central source for calling up material specific information within the
plant. Since all the material data is integrated in one master record, the problem of data redundancy is
minimized. This integration also enables the stored data to be used jointly by purchasing and other areas
such as Inventory Management, Material Request Planning (MRP), and Accounts Payable.

Plant Maintenance uses the following Material Types.

ZDIE SCALE Services
ZENS PM Spares Non Standardized Local
ZESS PM Spares Standardized Global
ZIMA Maintenance Assemblies
ZNFA Fixed Assets
ZNNM Non-Stock Materials
ZNVM Non Valuated Material

45 45
Material Masters

SAP Stock Item process flow
1. Materials List Display (MMBE)
2. P.R. List Display (MN53N)
3. P.O. List Display (ME23N)
Order - with Stock Item material

Released
Planned Wos
(ZP01, ZP03, etc)
Work Order
0010 Check pump
0020 Renew seals
Material
Issue/
Pick Lists
Problem
IDd
Create
Notificatio
n &
Release
Create order
(+ Materials) &
released
Received
materials
Confirm
order
TECO &
Close Order
Material

SAP Stock Item process flow

1. Create Notification & Release (IW21)

3. Goods Receive Process (MIGO)

4. Confirm order (IW41)
5. TECO and close order (IW32)
2. Create order, Add material & Release order (IW32)

Order - with Non-Stock Item Material
Released
Planned Wos
(ZP01, ZP03, etc)
Work Order
0010 Check pump
0020 Renew seals
Material
Issue/
Pick Lists
Problem

Create
Notificati
on &
Release
Create order
(+ Materials)
& released
PR Created
Automatically
Received
materials
Confirm
order
TECO &
Close
Order
Material

SAP Non-Stock item maintenance process flow
1. Create Notification & Release (IW21)

3. PR Created automatically

4. Good Receive (MIGO)
5. Confirm order (IW41)
2. Create order, Add material & Release order (IW32)

6. TECO and close order (IW32)
END

02 - SAP PM Plant Maintenance Universal Process Model

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