Ambuja Cements Ltd.

Plant Maintenance
PM00 PM Overview
Mumbai, 20-Feb-08
 Agenda

Objectives
APAC Plant Maintenance (PM) Overview
MAC Pyramid as Integrated in SAP-PM
PM Organizational Structure
PM Module Process Flows
Question & Answer

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Ambuja Cements Ltd. CONNECT IndiaPLUS
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 Objectives

To understand PM functionalities
To get to know technical terms used in PM module

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 Plant Maintenance

Sales & Distribution Financial

Accounting
Material Management SD FI
Controlling

Production Planning
MM CO
Asset Management
PP AM
R/3
Client / Server
Plant PM
Maintenance ABAP/4

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Ambuja Cements Ltd. CONNECT IndiaPLUS
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 APAC Plant Maintenance Overview

Automated recording of maintenance works and equipment

history
System integrated with Holcims MAC System Tools and
Elements
Sharing of current best practices in the APAC region and
Holcim group around the globe via MAC/SAP standards.
Online and real-time update of maintenance costs, integrated
with FICO
Integrated Material Master data with MM
APAC SAP-PM Master data Uses HAC (Holcim Asset
Coding) as Asset Numbering System
Compliant to Holcims HARP and MAC/SAP Standards.
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 The MAC Pyramid as Integrated in SAP
World Class
Maintenance
Integrated
Area Process Risk based
Process/
Work Maintenance Maintenance
Maintenance
Teams Teams (RbM)
System

Shutdown
Computerized
Multi Cycle Time Autonomous Business
Maintenance
Skilling Compression Maintenance Plan
Systems
(CTC)

Predictive
B.O.M. Maintenance Planned MTBF Plant
FMEA/ Routines/
Parts Master Maintenance MTTR Master
RCM Cond. based
List Schedule Routines MTBCF Plan
Monitoring

Spares Standards Asset Weekly Maintenance Resource

Weekly
Policy & and History Maintenance Cost Skills Budget
Plan
Management Specifications System Report Report Matrix

Asset Short
Works Daily Maintenance
Numbering Critical Daily Maintenance Interval Production
Order Maintenance Cost
System Assets Plan KPIs Control Plan
System Report Structure
(HAC/PNS) (SIC)

MAC/SAP Impacted No Impact

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 PM Organizational Structure
Maintenance Plant
Maintenance Plant NE03

Maintenance Planning Plant (Maratha Cement Works)

Maintenance Planner Group Maintenance Planning Plant

NE03
(Maratha Cement Works)
Work Centers
Planner Group
100

MTME01-I: LSC,RM Mech (Int)

MTEL03-E: Cem Mill, PP Ele (Ext)

MTAC02-I: Shift Maint A&C (Int)

MTMI01-I: Mining M/c Maint Mines (Int)

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 PM Organizational Structure
Client Plant

In commercial, organizational, and An organizational unit serving to

technical terms, a self-contained unit in
an R/3 System with separate master
records and its own set of tables. A
client can, for example, be a corporate
group.
The smallest organizational unit for which
a complete self-contained set of
accounts can be drawn up for purposes Company Code
of external reporting.
subdivide an enterprise according to
production, procurement,
maintenance, and materials planning
aspects. It is a place where either
materials are produced or goods and
services provided.

Maintenance plant Maintenance planning plant

The maintenance plant for a technical
object is the plant at which it is installed.
Ambuja Cements Ltd.
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The maintenance planning plant for a
technical object is the plant in which the
maintenance tasks for the object are
planned and prepared. Maintenance
planner groups work at the
maintenance planning plant to plan and
prepare the maintenance tasks for the
plants that are assigned to the
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maintenance planning plant.
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 PM Organizational Structure
Decentralized Planning

Ambuja Gaj-Ambuja Planning Plant

Ambuja Gaj-Ambuja
Plant

Centralized Planning

Darla Clinker Planning Plant

Darla Clinker Darla Cement Plant

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 Planned Maintenance Process Flow
Maintenance
Maintenance Strategy
Strategy

Task
Maintenance
Task List
List Task
Task List
List Task
Task List
List
Planners
Maintenance Maintenance Maintenance
Maintenance
Item
Maintenance
Item
Maintenance
Item
are responsible
Item Item Item
for the
Maintenance
Maintenance Plan
Plan PMR build-up.
Planned maintenance can
be performed within SAP on
a period basis (daily, Schedule
Schedule
weekly, monthly, etc.) or on Maintenance
Maintenance Plan
Plan
a performance basis (hours,
miles, kilometers, tons, etc.)
Deadline
Deadline Monitoring
Monitoring PM02 Orders
PM02 Orders
Auto-created & Released
(background
(background processing)
processing)
Preventive Orders

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 Work Order Process Flow
MM
Maintenance
notifications
purchase
requisitions goods
withdrawals
reservations
work
orders
Planned
maintenance RELEASE

Materials Work
Work steps, Execution
Planned hrs, confirmations
Manpower service entries CO FI
Investment External TECO
orders Services
Closed order
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 We

Know the way, show the way, go the way

Questions ?
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Ambuja Cements Ltd. CONNECT IndiaPLUS
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