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PLANT MAINTENANCE SYSTEM
2 Presentation Title | Confidential | Document ID | Dec 16, 2017

PLANT MAINTENANCE SYSTEM
I. MANAGING MASTERS
II. MANAGING MAINTENANCE PROCESSES
III. MANAGING REPORTS

I. MANAGING MASTERS

MAINTENANCE MASTERS
BASIC MASTERS CONTENTS OF MAINTENANCE

OF MASTERS
1. Functional Locations
Plant
2. Equipment Master Main Planner Group
3. Class & characteristics Plant Section
4. MICs Main Work Center
5. Work Center Cost Center /Internal Order
Category
6. Measuring Point
Company Code
7. Task List Master
Strategy
8. Maintenance Item UOM
9. Maintenance Plan

MAINTENANCE MASTERS
BASIC MASTERS CONTENTS OF MAINTENANCE

OF MASTERS
Function Location
2. Equipment Master
Structure
3. Class & characteristics
4. MICs Function Location Category
5. Work Center
Plant
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

FUNCTIONAL LOCATION STRUCTURE
Functional locations Structure is a hierarchical Presentation of a Tech.

System.
Gives information about how the Technical System is sub divided into
Individual Functional Units.
Individual function Units are defined on the Basis of Process Orientation,
Functions, or any other Special criteria.
Each functional location is managed independently in the system, so that
you can :
Manage individual data from a maintenance perspective for the object

Perform individual maintenance tasks for the object
Keep a record of the maintenance tasks performed for the object
Collect and evaluate data over a long period of time for the object

FUNCTION LOCATION STRUCTURE
Description Code
Structure Indicator GIL
Structure Indicator Text GIL Cement Division
Edit Mask AAA-AANN-AAX-AAX-XXX-XXXXX
Hierarchy Levels 1 2 3 4 5 6
Example
Hierarchy Edit Mask Code Description
Level
Level 1 AAA GIL Grasim Industries Limited
Level 2 AANN RC01 Raja shree Cement
Level 3 AAX RC1 Raja shree Cement Unit-I
Level 4 AAX CM1 RC1 Cement Mill-1
Level 5 XXX FEG RC1 Cement Mill -1 Feeding
Group
Level 6 XXXX

MAINTENANCE MASTERS
BASIC MASTERS CONTENTS OF FUNCTIONAL

LOCATION MASTER
1. Functional Locations Function Location Structure
2. Equipment Master
Function Location Category
4. MICs Plant
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

FUNCTION LOCATION CATEGORY
Category Description
C Colony Functional Locations

G General Functional Locations
H Hierarchical
M Plant & Machinery F Locations
N Mines Functional Locations
O Office Functional Locations
T Power Generation F. Locations
U Utility Functional Locations

NAVIGATE > SAP SCREEN
Display of Function Location-[IL03]
List Editing of Function Location-[IH06]
Display ( Multi Level) Function Location[IL07]
DISPLAY CONTENTS:
Display Action Log
Object Information

MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF MAINTENANCE

OF EQPT MASTER
1. Functional Locations Equipment Category

2. Equipment Master Plant
3. Class & characteristics Functional Location
Main Planner Group
4. MICs
Tech. Object Type
5. Work Center Plant Section
6. Measuring Point Main Work Center
7. Task List Master Cost Center /Internal Order
Company Code
8. Maintenance Item
Class
9. Maintenance Plan Warranty data

EQUIPMENT CATEGORY
Defining Equipment Categories is a facility in SAP/PM to

group the vast variety of Equipments that any manufacturing
Organization can have in their Plant. One of the methods of
grouping similar Equipments is to differentiate them on the
basis of their Use and / or the Function that they perform e.g.,
Electrical Equipment. In GIL, this is the basis of defining
Equipment Category shown in the next two slides

EQUIPMENT CATEGORY
CATEGO EQUIPMENT EXAMPLES

RY
A AUTOMOBILE CARS/JEEP/MOBILE VAN
C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS

D DUMMY EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR
TRANSFER. NOT TO BE USED
E ELECTRICAL EQUIPMENTS MOTORS/TRANSFORMERS/SWITCH
GEARS
I INSTRUMENT EQUIPMENTS RTDS/PROXIMITY SWITCHES/FIELD
INSTRUMENTS/PANELS
M MECHANICAL EQUIPMENTS GEAR BOXES/DPC/DBC/BELT
CONVEYORS
N MINES EQUIPMENTS SHOVELS/DUMPERS/DRILLING
MACHINES

EQUIPMENT CATEGORY
CATEGOR EQUIPMENT EXAMPLES

Y
P PROCESS EQUIPMENTS CYCLONES/HOPPERS
Q QC TEST EQUIPMENTS CUBE TESTING MACHINE /

COMPRESSIVE STR MACHINE
R PRODUCTION RESOURCES/TOOLS CRANES
T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER
U UTILITY EQUIPMENTS COMPRESSOR/WATER PUMPS
NOTE:
ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO
TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT
CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.

EQUIPMENTS CATEGORY & NUMBER RANGE
Number
Categor Number range
Description Range
y From
To
M Mechanical Equipments 10000000 19999999
E Electrical Equipments 20000000 29999999
I Instrumentation Equipments 30000000 39999999
P Process Equipments 40000000 49999999
T TPP & DG Equipments 50000000 59999999
N Mines Equipments 60000000 69999999
Automobiles Equipments
A 70000000 79999999
C Civil Objects & General Equipt. 80000000 89999999

S Safety Equipments 90000000 99999999
Q QC Test Equipments 1000000 1999999

TECHNICAL OBJECT TYPE
Technical Object Types are the logical grouping of Objects on the

basis of similarity of function being performed by each one.
Examples :
ME_GEARBOX Gear Box
EL_MOTORS Electrical Motors
ME_FANS Fans

PLANNING PLANT
Plant in which maintenance tasks are planned and executed. In GIL ,

Planning Plant is also a Maintenance Plant. Different Planning Plants in GIL
are :
Aditya Cement
Grasim Cement
Vikram Cement
Rajashree Cement
Grasim South
Birla Super Cement (Hotgi)
Birla Plus Cement (Bhatinda)

MAIN WORK CENTER
Main Work Center is Logical Grouping of all Work Centers, which are
Performing similar nature of Maintenance Tasks/Activities in different
Plant Sections. E.G. Mechanical Main Work Center is a Group of Plant
Maintenance Persons, who are executing Mechanical Maintenance
activities . Different Main Work Centers defined are :
Mechanical Department
Electrical Department.
Instrumentation Department.
Process Department.
Civil Department, Etc.

PLANT SECTION
Plant Section is a division of Maintenance Plants into Production

Areas.
Plant Category Description
GC01
RM1 Raw Mill -1
GC01
CO1 Coal Mill -1
GC01
KL1 Kiln -1
GC01
CM1 Cement Mill -1
GC01
PP1 Packing Plant -1

PLANNER GROUP
Planner Group defines the Group of People (Employees) responsible

for Planning and Execution of Maintenance Activities in a Particular
Plant.
PLANNER GROUP CODIFICATION LOGIC
PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION
MCM = Mechanical + Cement Mill

ECM = Electrical + Cement Mill
ICM = Instrumentation + Cement Mill

COST CENTER/ INTERNAL ORDERS
Cost Centers are logical Organizational Units where the costs are
incurred for value addition . Costs incurred are ultimately settled to Cost
Centers through Orders.
Internal order is nothing but an intermediate cost collector between PM
order and cost center. Internal Order will be used in Mines Equipment
only.
Cost Center Concept as applied in GIL :

Plant Section = Superior Cost Center
Department = Sub Cost Center in that Plant section
CEMENT MILL
Mechanical Electrical Instrumentation Process

Creation of Equipment-[IE01]
Change of Equipment-[IE02]
Display of Equipment-[IE03]
List Editing of Equipment-[IH08]
Display ( Multi Level)-[IE07]
DISPLAY CONTENTS:
Display of Usage List

Display Action Log
Display Object Information
Installation & Dismantle

MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF CLASS &

CHARACTERISTICS MASTERS
Class Type
2. Equipment Master
Class Group
Characteristics Group
4. MICs
Unit of Measure for
5. Work Center
Characteristics Master
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

CLASS
Classes are :
Logical Grouping of Equipments having Similar Functions.

Class Mainly Depends on the Main Function / Activity being
Performed by that Equipment.
It helps to know the Number of Equipments having the same
Class.
Class data will never Change throughout the entire Productive
Life-Cycle of the Equipment.
This information can be used for Proper Planning of Spares,
for planned Maintenance & obtaining the History of that Class
of Equipments.

CHARACTERISTICS
Characteristics are the Specifications or Designed Parameters of

Measurement for the Equipments. Ex. Flow of Fan , Gear Ratio of Gear
Box.
Combination of Class and Characteristics helps in Precise search of
Equipments.
For Example:
Select Gearbox of Particular Make / Ratio.

Select Class as Gearbox & Characteristics as Make/ Ratio. Enter
Relevant Values of these Characteristics.
System will search & display all Gearboxes satisfying above
Characteristics Values

CLASS
Mechanical Electrical
Class Description Class Description
GEARBOX GEARBOX LTMOTOR LT MOTOR
BUCKETELELVATOR BUCKET ELELVATOR LTFEEDER LT FEEDER
BALLMILL BALL MILL BATTERY BATTERY
BAGHOUSE BAG HOUSE BREAKER BREAKER

CLASS AND CHARACTERISTICS GROUPS CODES
Char. Group Code Description

PM_EQ_ELEC PM Elec. Equipments Specs.Char. Group
PM_EQ_GENL PM General Equip. Specs. Class Group
PM_EQ_INST PM Inst. Equipments Specs.Char. Group
PM_EQ_MECH PM Mech. Equipments Specs.Char. Group
PM_EQ_MINE PM Mine. Equipments Specs.Char. Group
PM_EQ_PROC PM Proc. Equipments Specs.Char. Group
PM_EQ_SAFE PM Safety Equip. Specs. Char Group
PM_EQ_TPDG PM TPP & DG Equip. Specs. Char. Group

Display of Class List [CL03]
Find Object in Class- [CL30N ]

MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF MICs MASTER
Plant
2. Equipment Master Range of Characteristics Value

4. MICs
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

MASTER INSPECTION CHARACTERISTCS
Specific parameters of an Equipment for Calibration

Parameters to measure whether Equipment is performing its function
The Parameter driving / governing Equipment performance/Output is
within acceptable limits.
Example: Mili-amperes / Mili-volts for weigh Feeder

Find out The Maintenance Inspection Characteristics prepared-[QS24]

MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF WORK CENTER

MASTER
Plant
2. Equipment Master
Work Center Category
Control Key
4. MICs
Cost Center
5. Work Center
Work Dimension - Time
6. Measuring Point
Work Unit
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

WORK CENTER
Work Center is a Person/Group of Persons, who perform Maintenance Activities.
Work Center Category
Each Department will have two categories, Permanent and Contractor.
Category Description
0021 Mechanical Permanent
0022 Mechanical Contractor
Example : M1F1W3K, MC1F1W3K etc.
Codification Logic :
M1F1W3K = Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi

MC1F1W3K = Mech. Contractor / 1 Fitter /1Welder / 3 Khalasi

Work Center List-[IR03]
DISPLAY CONTENTS:
Relevant Number for Permanent and Contractor Work centers
for your department.
Different combinations of Skills.

MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF MEASURING

POINT MASTER
Equipment Master
2. Equipment Master
Function Location Master
Category of Measuring Point
4. MICs
Characteristics
5. Work Center
Unit of Measures
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

MEASURING POINT
It is a Measurement characteristic/Parameter attached to an Equipment
Describe the Physical and/or Logical Locations of Equipment

at which a Condition / Parameter is to be measured.
Measuring Point will be always for an Equipment or FL or assembly

but Generally for Equipments.
Measurement readings are taken for an Equipment at regular

interval to know the Condition at that time.

MEASURING POINT Continued..
Measuring Point is also Used as Counter where values Measured

by a Measuring Point can be summed up during a time period for
monitoring and control .
Example:
Running hours of Any Equipment
Lubrication Consumption.

NAVIGATE > SAP SCREEN(MP)
Creation Of Measuring point [IK01 ]
Change / Display Of Measuring Point [IK02/ IK03]
Display List Editing-[IK07]
Create Entry List-[IK31]
Collective entry of measuring document-[IK34]
DISPLAY CONTENTS:
Transfer of Measuring point

MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF TASK

LIST MASTERS
1. Function Locations
Group Coding
2. Equipment Master
Counter
Planning Plant
4. MICs Maintenance Strategy
5. Work Center Work Center
6. Measuring Point Set of Operations
7. Task List Master MIs
8. Maintenance Item
9. Maintenance Plan

TASK LIST
A Set of Activities to be Performed on an Equipment or Functional

Location.
Three types of Task Lists :

Functional Location Task List[T]
Equipment Task List[E]
General Task List[A]

TASK LIST CODIFICATION
seq Codification Logic for defining Task List Group - It has to be Planning Plant / Maintenance Specific
1 XX GIL Plant Short Code:
RC = RC01, GS = GS01, GS = GS01, GC = GC01, BS = BS01.

2 X Discipline:
E = Electrical, M = Mechanical, I =Instrumentation, P = Process, N = Mines, T = TPP, Q

= QC,S = Safety
3 XX Equipment Short "Equipment Class Code":
GB = Gear Box, BF= Bag Filter, BC = Belt Conveyor, AT = Analyzer, MO= DC Motor, etc
4 X Equipment Class Code Type( application) :
GB Gear Box Helical; Radial; BE-Bucket Elevator Belt/ Chain

5 XX Type of Maintenance Task List:
PM=Preventive Maintenance , AM = AMC Tasks, CA= Calibration ; SD = Shutdown , IN

= Inspection (attribute/Value EN-Environment;) J-Jishu Hozen ( General Inspection ) ZX-
Safety
Example: GCMGBHPM GCM-GBH-PM 1M Checks
GCEMODPM GCE-Motor-DC-PM 3M Checks

MAINTENANCE STRATEGY
Set of Predefined Prefixed Time Intervals ( Called Packages) grouped

at Which Preventive Maintenance Activities can be taken Up.
These Maintenance Strategies can be selected By User to carry out
Maintenance Activities depending Upon :--
Age of Equipment
Design of Equipment
Importance of Equipment in Production Process
Maintenance Practices of Organization.

MAINTENANCE STRATEGIES Continued..
GILDAY -- Frequencies Specified in GILDAY

Are 1W / 2W / 1M / 3M / 6M / 1Y
GILMON-- Frequencies Specified in GILMON

Are 6M/ 1Y/ 2Y/ 5Y
MINEHR -- Frequencies Specified in MINEHR

Are 100HR/ 300HR / 350HR/ 400HR
PERFHR -- Frequencies Specified in PERFHR

Are150HR / 250HR / 500HR/ 1000H

APPLICATION: Continued..
GILDAY: Strategy is Used for Frequencies of Check Up to 6M.
GILMON: Strategy is Used for Frequencies of Checks More than 6M.
MINEHR: Strategy is Used For MINES Preventive Maintenance Planning.
PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance

Planning.

MAINTENANCE PACKAGE
Strategy GILDAY
Cycle Length UOM Maintenance Cycle Text Cycle Short Text

7 DAY Weekly (1 Week ) 1W
14 DAY Fortnightly (2 Weeks ) 2W
28 DAY Monthly ( 4 Weeks ) 1M
84 DAY Quarterly ( 12 Weeks ) 3M
168 DAY Half yearly ( 24 Weeks ) 6M
336 DAY Yearly ( 48 Weeks ) 1Y
Strategy GILMON

6 MON Half yearly 6M
12 MON Yearly 1Y
24 MON 2 Yearly 2Y
48 MON 5 Yearly 5Y

MAINTENANCE PACKAGE
Continued..
Strategy MINEHR

96 HR 100 Running Hours ( 96 Hrs) P1
504 HR 500 Running Hours ( 504Hrs) P5
1008 HR 1000 Running Hours (1008 Hrs) P6
3000 HR 3000 Running Hours ( 3000 Hrs) 1P

MAINTENANCE PACKAGE
Continued..
Strategy PERFHR

144 HR 150 Running Hours ( 144 Hrs.) P1
12096 HR 12000 Running Hours (12096 H) P8
16128 HR 16000 Running Hours ( 16128 H P9
24192 HR 24000 Running Hours ( 24192 H 1P
32256 HR 32000 Running Hours ( 32256 H 2P

Display Task List-[IA07]

List Editing Task List-[IA09]
DISPLAY CONTENT:
Find Task Lists in your Planner group.

MAINTENANCE MASTERS

ITEM MASTER
Equipment /Function Location
2. Equipment Master
Master
3. Class & characteristics Task list Master
4. MICs Strategy
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

MAINTENANCE ITEM
Maintenance Item describe Preventive Maintenance Tasks

to be performed on an Equipment at Predefined Interval
Maintenance Item = Equipment + Task List with set of operations

with Maintenance Package

MAINTENANCE MASTERS

PLAN MASTER
Maintenance Item Master
2. Equipment Master Strategy
3. Class & characteristics Scheduling parameter
4. MICs
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

MAINTENANCE PLAN
Maintenance Plan is the Scheduling of Task List attached to an

Equipment (Maintenance Item ) on Time Scale ( According to
Factory Calendar ) or Performance scale ( According to Counter
i.e. Number of Hours).
Plan = Maintenance Item + Scheduling Parameters

MAINTENANCE SCHEDULING PARAMETER
TOLERENCE: ( 50% )
It is the difference between planned date and TECO date ,given in %age for
deciding whether maintenance cycle should be shifted or not, considering
the gap between planned date and TECO date.
Shift factor will be effective only if difference between planned date and
TECO date is more than 50% of smallest interval (smallest package) , either
+ or side. If difference between planned date and TECO date is less than
50% of smallest interval (smallest package) , there will be no shift. For
GILDAY , it will be + / - 3.5 days , as minimum frequency is 1w. For GILMON
it will be +/- 3 months as min freq is 6M.
SHIFT: 100% .
If condition given in Tolerance is true it will shift the maintenance cycle
by : given shift % x difference between planned date and TECO date .i.e.
Actual delay

MAINTENANCE SCHEDULING PARAMETER
Continued..
CALL HORIZON 50%
It indicates that an advance intimation of planned maintenance will be

given by 0.5 x minimum frequency of strategy selected through order
generation .
FOR GILDAY :
1W Being minimum frequency , you will get weekly order 3.5 days
in advance if call horizon is 50%.

II. MANAGING MAINTENANCE PROCESSES

MAINTENANCE PROCESSES
BASIC PROCESSES BASIC STEPS OF MAINTENANCE

PROCESSES
1. Preventive Maintenance Creation of Notification
Creation of Orders
2. Break down Maintenance
Execution of Orders
3. Shut down Maintenance Confirmation of Orders
4. Condition base Maintenance Technical Confirmation of
5. Work shop Repair Orders
6. External Repair/Services Creation of Purchase Request
Creation of Purchase Orders
7. Calibration
Service Entry Sheets
Creation of Measuring Points
& Measuring Documents
Installation / De-installation of
Equipments
1. PREVENTIVE MAINTENANCE PROCESS
BASIC PROCESSES
1. Preventive Maintenance BASIC STEPS OF PREVENTIVE

MAINTENANCE PROCESS
Selection of Orders
3. Shut down Maintenance
Execution of Orders
4. Condition base Maintenance
5. Work shop Repair Confirmation of Orders
6. External Repair/Services Technical Completion of

7. Calibration Orders

Selection of Order H/L TO ORDER TYPES
BASIC STEPS OF MAINTENANCE

Go to T. Code - IW39
PROCESSES
Selection of Orders Flag Outstanding & In process
check box
Execution of Orders
Enter Order Type PM01 Select from Drill Down
Confirmation of Orders
Technical Completion of Orders Enter Period ( Date from..to
)
Enter Status exclusive in CRTD, CNF ,

Multiple Selection TECO & CLSD
Enter Maintenance Plant
Enter Planner group for Order Select from Drill Down
Execute by clicking
button
Order list of relevant section

Appears

ORDER TYPES
PM01 --- PREVENTIVE MAINTENANCE ORDERS
These Orders are Planned by SAP System
User can not generate PM Work Order for this Order Type externally.
This Order type will help User to find out Cost of Preventive Maintenance
exclusively for his Plant section/Planner group.
User will be able to compare Cost Of Preventive Maintenance vis--vis

Breakdown and Shutdown Maintenance.
User will be able to judge the effectiveness of Preventive Maintenance Plans by

this Order Type.
Order Numbering is blocked for this Order
User will get Preventive Maintenance Orders under Maintenance Activity Type -
PVM , Annual Maintenance Contract Orders under Maintenance Activity Type -
AMC and Inspection Orders under Maintenance Activity Type INW

ORDER TYPES
Continued..
PM02: BREAKDOWN MAINTENANCE ORDERS
This Order Type is exclusively for Breakdown registration of Equipments
This Order Type indicates Unplanned stoppage in Production Process
In addition to consumption of Recourses like Men , Machine , Material ,

Production loss is also associated with this type of Order .
User can further segregate the breakdowns of Equipments under Warranty /

Insurance from other Breakdowns.
PM03: SHUTDOWN MAINTENANCE ORDERS

This Order Type indicates
Annual Shutdowns ( Maintenance Activity Type: SDM)
Planned Weekly,Fortnightly,Monthly Stoppages ( Maintenance Act. Type : WFM)
Opportunity Based Maintenance (Maintenance Activity Type: OPP)

The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be
booked under MAT- SDM.

ORDER TYPES
Continued..
PM03: SHUTDOWN MAINTENANCE ORDERS
Only Planned Weekly,Fortnightly,Monthly Stoppages will be booked under Maintenance

Activity Type WFM
Other Maintenance jobs not planned but undertaken because of availability of Opportunity are
booked under MAT-OPP.
PM05: CALIBRATION MAINTENANCE ORDERS
This Order Type is applicable for Calibration of Equipments

These Orders are Planned by System . However , User can also raise Order externally , if
required for unplanned Calibration jobs.
This Order Type has MAT- CAL .
PM06 : CORRECTIVE MAINTENANCE ORDERS
The jobs covered under this Order Type are of 2 types:

Corrective Actions suggested under WHY-WHY Analysis to avoid recurrence of Breakdown will
be covered under Maintenance Type WHY .

ORDER TYPES
Continued..
PM06 : CORRECTIVE MAINTENANCE ORDERS

Other Maintenance Jobs of Corrective Nature e.g. Maintenance Requests from other
departments , Removal of Abnormalities/Defects, Removal of Unsafe Conditions where
Breakdown has not occurred will be covered under MAT- CRM
PM07 --- CONDITION BASED MAINTENANCE ORDERS

This Order Type is applicable for jobs planned on the basis of Condition of Spares. E.g.
Replacement of Worn Out Chain/ Worn-out Hammers etc
MID , being Condition Monitoring Department , will use this Order Type for advising repair /
replacements on the basis of Condition E.g. Hardness/Thickness/Vibrations etc
PM08 --- GENERAL MAINTENANCE ORDERS

This Order Type is applicable for UNDEFINED jobs NOT FALLING under above categories
and not related to Equipment. E.g. Leakage of Water Tap in Administration Building garden.
These are of Minor nature Repair Jobs.
This Order Type should not be used unless it satisfies above condition

ORDER TYPES
Continued..
PM09: REPAIR MAINTENANCE ORDERS
There are Four different Activity Types or jobs covered under this category. They are:
Work Shop jobs should be registered under MAT RWS

Rewinding jobs should be registered under MAT - REW
Tyre Retreading jobs should be registered under MAT RET
External Repair jobs should be registered under MAT RVN
PM10: IMPROVEMENT/MODIFICATION ORDERS
All jobs of Improvements and Modifications in Maintenance (Reliability

MTTR/MTBF/Maintainability/Availability) are covered under Maintenance Activity Type IMO
Suggestions given by Consultants/Experts/Other Units/ Other sources like

Websites, Manuals, Magazines etc are covered under Maintenance Activity Type CON.
PM11: CAPEX/BLOCK ORDERS
All Work Orders raised for Project Work are covered under this Order Type and MAT-
CAP
PM12 --- CIVIL MAINTENANCE ORDERS
All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/
Foundation
64 etc are covered
Presentation under| this
Title | Confidential Order
Document Type
ID | Dec and MAT-CIV
16, 2017
MAINTENANCE ACTIVITY TYPES IN PM ORDERS
Order Type Description Order Activity Type
PM01 Preventive Maintenance Order PVM,AMC,INW
PM02 Breakdown Maintenance Order BDM,WAR,INS

PM03 Shutdown Maintenance Order SDM,OPP,WFM
PM05 Calibration Order CAL
PM06 Corrective Maintenance Order CRM,WHY
PM07 Condition Based Maintenance CBM
PM08 General Maint Order GEN
PM09 Repairs Order RWS,RVN,RET,REW
PM10 Improvement/Modification Order IMO.CON
PM11 Capex / Block order CAP
PM12 Civil Maintenance Order CIV
QCAL QC Insp./ Calibration Order CAL

Selection of Order H/L TO ORDER TYPES

PROCESSES
Selection of Orders Flag Outstanding & In process
check box
Execution of Orders
Enter Order Type PM01 Select from Drill Down
Technical Completion of Orders Enter Period ( Date from..to
)
Enter Status exclusive in CRTD, CNF ,

Execute by clicking
button

Appears

PROCESSES
Select desired order
Selection of Orders
Execution of Orders Move to SAP Screen
Technical Completion of Orders

Execution of Orders
PROCESSES
Selection of Orders
Enter number of Selected Order
Execution of Orders
Order status will be
Confirmation of Orders Release PM01 Type Selected changed to REL from
Technical Completion of Orders Order CRTD
Go to Operation TAB and

Change operations etc if reqd
Select operation & Go to

Component TAB if Material
Required
Select required Component
Enter reqd Qty , Item category,

Storage Location & Batch
Come to Header data Tab
Enter Start Date & Time

Schedule Order by Clicking End date & time will

BASIC STEPS OF MAINTENANCE be changed by system
PROCESSES Determine cost by clicking
Selection of Orders
Execution of Orders Save the Order
Technical Completion of Orders Move to SAP Screen

Confirmation of Order
PROCESSES Go to T. Code IW44
Selection of Orders Select Header Menu

Execution of Orders Confirmation
Confirmation of Orders Select via operation list in

Confirmation Menu
Selection of operation list
appears
Enter Plant
Enter Order type Select from Drill Down
Enter Reference date
Enter Planner group
Enter Status Exclusive in Multi CRTD, CNF ,

Selection List TECO & CLSD

Execute by clicking button
PROCESSES All relevant Orders with
Selection of Orders Operations will be copied on
Execution of Orders main screen
Technical Completion of Orders Select All Operations
Click All Actual Data on Header

Tool bar
All Planning data of operations

defaulted from relevant Orders
Enter Actual Work Center Qty
Flag Final confirmation, Clear all

Res & No remaining work
Enter Start Date & Time
Enter End Date & Time

BASIC STEPS OF MAINTENANCE Enter Actual Duration

PROCESSES
Selection of Orders Enter Confirmation Text
Execution of Orders
System will calculate Actual
Confirmation of Orders Duration
Save Confirmation by clicking
Move to SAP Screen

Technical Completion of
Order
PROCESSES Go to T. Code - IW32
Selection of Orders
Execution of Orders Selection of Order Screen
Confirmation of Orders appeared
Orders Flag In process check box
Enter Order Type PM01
Enter Period (Date fromto)
Enter Status exclusive in CRTD, REL ,

Execute by clicking
button

Appears
PROCESSES Select order and click
Selection of Orders
Execution of Orders Order Main Header Screen
Confirmation of Orders Opens
Technical Confirmation of
Click Settlement Rule button
Orders
Enter / change cost center &
give % if required
Click Flag of Technical

Completion
Enter Reference Date & Time
Click Enter Button
Order is Technically Completed

& System Status Changed to
TECO
Move to SAP Screen

2. BREAKDOWN MAINTENANCE PROCESS
BASIC PROCESSES BASIC STEPS OF BREAKDOWN

MAINTENANCE PROCESS
1. Preventive Maintenance Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
4. Condition base Maintenance Execution of Orders
6. External Repair/Services Technical Completion of Orders
Execution & Completion of
7. Calibration
Notification
Why-Why Analysis

Creation of M2 Notification Manual Process
BASIC STEPS OF
MAINTENANCE PROCESSES Go to T. Code IW21Create
Creation of M2-Notification Notification
Selection of M2-Notification Select from Drill Down
Enter Notification Type
Creation of PM02-Order H/L TO N/F Types
Selection of Order Do not Enter Notification System Generated

Number
Execution of Orders
Notification Tab Screen Appears
Click Enter Button
Notification
Why-Why Analysis Enter Notification Description
Enter Equipment / FL /
Assembly (as required)
Enter Reported By (Name)

NOTIFICATION TYPES Continued..
M1 --- MAINTENANCE REQUEST
This Notification type indicates a request made by Customer department to his

Supplier/Service Provider. E.g Request made by Raw Mill Mechanical for repair of
Gear Box shaft on Workshop.
This includes all types of jobs of Maintenance/Repair/Service requests made by User

on Service Provider EXCEPT Malfunction/Breakdown.
M2 --- MALFUNCTION/BREAKDOWN
This Notification Type is exclusively for information regarding Breakdown of

Equipments
This Notification is raised generally by Production on relevant Maintenance
Department as a FIR of Unplanned stoppage in Production Process.
However , anybody can raise this Notification if it satisfies above condition.

M3 --- UNSAFE CONDITION/ACCIDENT
This Notification is an information from any department including Safety

regarding prevailing Unsafe/ Hazardous Condition which is dangerous and may
cause damage to Property/Human being / Environment /Surroundings etc , to
the relevant department responsible for such condition for necessary corrective
action.
M4 --- ABNORMALITY RECORD
This notification is raised to register 7 types of Basic Defects in Equipments.

These defects are revealed through Daily Check List/ Inspection/Plant Round
Satisfies the WCM requirement to monitor 7 type of basic defects which are
responsible for Breakdown , if not corrected in time.

M5: RECOMMENDATION/IMPROVEMENT
This Notification is generated by User for any improvement/development to be

implemented .
The source for Improvement/Modification/Development in Reliability/ Availability
/Maintainability may be WHY-WHY Analysis, Experts/Consultants
recommendation/Other Units/KIPs etc
The number of such Notifications will be an indicator of improvements done by
User
These notifications will give List of Improvements done by User which is required
by WCM or for sharing with other Units.
M6 --- WORK REQUEST-WORKSHOP
This notification is raised by User on workshop requesting its services for

Repair/Machining/Replacement of Spares/Assembly/Equipment etc.

M7: GENERAL NOTIFICATION.
Notification which does not fall in any of the conditions mentioned above may be
raised in this type.
This type of Notification should not be used as far as possible as it will affect
history/vital information about Equipments.
M8: MEASURING POINT ERROR
This notification is raised by the SAP system automatically whenever the

Parameter defined as a Measuring Point deviates from its Standard Value or goes
beyond its Acceptable Permissible Value.

Notification Types
Notification Type Description Number Ranges From -To

M1 Maintenance Request 1000000000 to 1999999999
M2 Malfunction, B/Down 2000000000 to 2999999999
M3 UnsafeCond./Accident 3000000000 to 3999999999
M4 Abnormality Record 4000000000 to 4999999999
M5 Recommendation 5000000000 to 5999999999
M6 Work Request- W.Shop 6000000000 to 6999999999

BASIC STEPS OF
Selection of M2-Notification Select from Drill Down
Enter Notification Type
Selection of Order Do not Enter Notification System Generated

Number
Execution of Orders
Notification Tab Screen Appears
Click Enter Button
Notification
Why-Why Analysis Enter Notification Description

Popup Massage of warranty If equipment Under
BASIC STEPS OF warranty
Prompts
Creation of M2-Notification Enter Code of STD TEXT
Attached
Main Work center/ Planner
Creation of PM02-Order All information Defaulted
Group etc Defaulted & can be from equipment master
Selection of Order Changed If Required
Execution of Orders
If Reqd Enter Long Text
Go To Location Data Tab
Notification Flag breakdown check box
Why-Why Analysis
Release & Save the Notification
In case of Main Plant, M2 Type

Notifications will be Generated
by System thru breakdown
entry made by CCR
Naviaget >SAP Screen

Selection of M2 Notification
BASIC STEPS OF
MAINTENANCE PROCESSES Go to T. Code IW28 Selection
of Notification
Creation of M2-Notification
Selection of M2-Notification Flag check box Outstanding or
In process (as Reqd)
Selection of Order Enter Notification Date
Execution of Orders Enter Planner group

Confirmation of Orders Select from Drill Down
Technical Completion of Orders Enter Maintenance Plant
Execution & Completion of Click Enter Button

Notification
List of Notifications Appears as
Why-Why Analysis
per Selection Criteria
Select relevant Notification
Click on Details Button
Notification Change Screen

Appears

Navigate. SAP Screen
Creation of PM02 Type Order
BASIC STEPS OF from Notification
M2 Notification selected in
Changed Mode as explained in
Selection of M2-Notification pervious sheet
Click Create button
Selection of Order
Execution of Orders of Order Tab
Confirmation of Orders Create Order Popup Screen

Technical Completion of Orders Appears with Defaulted data
from notification
Enter PMActType BDM & click Select from Drill Down
Notification
continue button & save
Why-Why Analysis
Breakdown Order Created
Further process of order will

remain same as explained in
process 1. Preventive
Maintenance
Navigate> SAP Screen

BASIC STEPS OF
MAINTENANCE PROCESSES Process of Selection of Order,
Creation of M2-Notification Execution of Order, confirmation
& TECO will be similar to processes
Selection of M2-Notification explained in process
Creation of PM02-Order 1. Preventive Maintenance
Selection of Order
Execution of Orders
Notification
Why-Why Analysis

Execution of M2 Notification
BASIC STEPS OF (Order not generated)
M2 Notification selected in
Creation of M2-Notification Changed Mode as explained in
Selection of M2-Notification pervious Process
Creation of PM02-Order To Attach Std Text Go to Effect Select from Drill Down
Selection of Order field & select relevant code of
Std Text
Execution of Orders
Confirmation of Orders Insert Text popup screen
Technical Completion of Orders appears.
Execution & Completion of On Insert Text screen Flag Select from Drill Down
Notification Expand immediately , enter Text
ID ST & click on dropdown of
Why-Why Analysis Text Name field
Next Popup screen Database

selection for SAP script text
Execute Popup screen

Database selection for SAP
script text without entering any
data
BASIC STEPS OF Next Popup screen Find SAP Select from Drill Down
script text will appear. Select
relevant text & click continue
Creation of M2-Notification button
Creation of PM02-Order Now popup screen Insert Text
appear again with text attached.
Selection of Order Click Continue Button
Execution of Orders
Confirmation of Orders Desired Standard Text Get
copied in long text. Complete it
Technical Completion of Orders & go back to main screen
Notification Select malfunction& downtime
tab and Enter down time end
Why-Why Analysis Date &Time.
Click Complete Flag and

complete Notification

BASIC STEPS OF Create Why Why Analysis
MAINTENANCE PROCESSES Sheet
Creation of M2-Notification Go to T. Code -- ZRPM-WHY

Creation of PM02-Order Enter Plant , Plant Section & Select from Drill Down
Planner group
Selection of Order
Execution of Orders Enter Date Range (From...To)
Select status by flagging and
Technical Completion of Orders execute
Notification List of Notification appears (as
per selection criteria)
Why-Why Analysis
Select relevant notification &
double click it
Why Why Analysis screen

Appears

BASIC STEPS OF Enter Object Code Select from Drill Down
Enter Damage Code Select from Drill Down
Selection of M2-Notification Enter all Possible Causes Select from Drill Down
Creation of PM02-Order (Possible reasons)
Selection of Order
Flag YES box to actual Cause
Execution of Orders
Confirmation of Orders Enter Observations
Enter Analysis In Why Why
Execution & Completion of Field
Notification
Enter Rectification carried out
Why-Why Analysis
Enter Recommendations
Enter Responsible person and

Tar Date for Recommendations
Select Document Attached -

Say 2

BASIC STEPS OF Next procedure of Standard text
shall be similar as explained in
Process Execution of M2
Click Complete Flag and
Creation of PM02-Order Complete Notification
Selection of Order
Save why-why Analysis
Execution of Orders
Confirmation of Orders Change Why Why Analysis
Go to T. Code ZRPM_WHY
Notification Go to Main screen of selected
Why-Why Analysis Notifications why why analysis
Click Put in Process Flag
Change Why Why analysis data

as per requirement
Save changed why-why

Navigate> SAP Screen Analysis

3. SHUTDOWN MAINTENANCE PROCESS
BASIC PROCESSES BASIC STEPS OF SHUTDOWN

MAINTENANCE PROCESS
1. Preventive Maintenance Creation of PM03 - Shutdown
2. Break down Maintenance Orders

Selection of PM03 - Shutdown
Orders
4. Condition base Maintenance Report of Shutdown Planning
5. Work shop Repair Creation of Direct Purchase
6. External Repair/Services Order
Creation of Direct Purchase
7. Calibration
Request (Indent)
Execution of Orders

BASIC STEPS OF SHUTDOWN Creation of Shutdown Order

MAINTENANCE PROCESS
Creation of PM03 - Shutdown Go to T. Code IW31
Orders Enter Order Type - PM03 Select from Drill Down

Selection of PM03 - Shutdown
Enter Equipment Number By Drill Down go to
Orders selection screen
Report of Shutdown Planning Equipment selection screen
appears
Order Enter Equipment Class (Optional) Select from Drill Down
Equipment Category - M Select from Drill Down
Request (Indent)
Report of Shutdown Planning Maintenance Plant Select from Drill Down
Execution of Orders Enter plant Section Select from Drill Down

Enter Planner Group Select from Drill Down
Click Execute Button

Select Desired Equipment &
BASIC STEPS OF SHUTDOWN click . Equipment entered in
MAINTENANCE PROCESS field
Creation of PM03 - Shutdown
Enter Planning Plant & Enter Select from Drill Down
Orders
Selection of PM03 - Shutdown Create Shutdown
Orders Maintenance Order : Central
Header Screen appears
Report of Shutdown Planning
Creation of Direct Purchase Enter Order Description
Order Go to Header data Tab & Enter
Creation of Direct Purchase PMActTYPE - SDM
Request (Indent) Go to Operation Tab and Enter
Operations as required
Execution of Orders
Confirmation of Orders Enter Relevant Work Center Select from Drill Down
Technical Completion of Orders Enter Relevant Control key
Better to Create Separate Order

for PMIN & PMEX Control key
Pl Refer Next Slide

PMIN PMEX
After Assigning Control Keys
Enter Work or Duration Select Operations
Enter WC Qty and Cal.Key Click on External Button
Popup screen External

Activity type Defaulted
Processing Operation appears
Select Operation & Go to Select

Select Material Group ( S524
from Drill
Component TAB if Material For External Services) & Pur. Down
Required Group
Select Enter Vender , tracking No & Select

Enter required Material, qty, from Drill from Drill
click
S.Loc (see stock) & Batch Down Down
Select External Processing operation

Again Go to Operation screen
from Drill Appears
Enhancement Button and
Down
enter Field key ZPM0001, Select
Position Go to service tab & Select
from Drill
Desired Services from Service Down
Master or write Description only
Click Gen Data Button & Get & Enter Required Quantity
Reservation Number on comp
detail screen & come back Enter Cost Element & Press
Enter

Click scheduling & determine Enter Cost Element & Press
cost button Enter
Create Purchase Requisition

For Release Order Press Icon
screen appears. Enter Dept and
Press Enter
Save Order by click button
Repeat above three steps for
Navigate> SAP Screen Next Operation's
Go to Header Screen & Click

Determine cost button
You can
See PR No
Thru GEN For Release Order Press Icon
data->Act
data Tab
Save order by click button

BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Orders
Selection of PM03 -
Shutdown Orders Process of Selection of
Order, Execution of Order,
confirmation & TECO will be
Creation of Direct Purchase similar to processes
Order explained in process
Creation of Direct Purchase 1. Preventive Maintenance
Request (Indent)
Execution of Orders
Orders

Report1. of Shutdown
BASIC STEPS OF SHUTDOWN Planning
MAINTENANCE PROCESS
Go to T. Code IW49N
Orders Display order & Operation:
selection of order & Operation
Selection of PM03 - Shutdown screen appears
Orders
Report of Shutdown Planning Flag Outstanding & In process
Order
Order Enter Order type Select from Drill Down

Enter Main work center Select from Drill Down
Request (Indent)
Execution of Orders Enter Period (dates)
Maintenance Plant Select from Drill Down
Enter Plant Section Select from Drill Down

BASIC STEPS OF SHUTDOWN Click Execute Button

MAINTENANCE PROCESS
Creation of PM03 - Shutdown Report of Order with Operation
etc Appears
Orders
Selection of PM03 - Shutdown View Reports with Relevant
Layout selection
Orders
Report of Shutdown Planning Navigate> SAP Screen
Order
Request (Indent)
Execution of Orders

Report 2 of Shutdown
BASIC STEPS OF SHUTDOWN Planning (MATERIAL)
MAINTENANCE PROCESS
Creation of PM03 -Shutdown Go to IWBK Material
Availability Check (for orders)
Orders
Selection of PM03 -Shutdown Material availability Information
screen
Orders
Report of Shutdown Planning Click Multiple Selection of Order
Creation of Direct Purchase Field
Order Click Multiple selection button Select from Drill Down

Request (Indent) Flag outstanding & In process
Execution of Orders Enter Order Type- PM09
Technical Completion of Orders Enter Period (dates)
Maintenance Plant Select from Drill Down
Enter Plant Section Select from Drill Down

Click Execute Button
MAINTENANCE PROCESS Report of Order with Operation
Creation of PM03 -Shutdown etc Appears
Orders
Go to back to Multiple selection
Selection of PM03 -Shutdown screen & Execute
Orders
Report of Shutdown Planning Paste Selected Orders &
execute
Order You will reach back to main
screen of Material availability
Creation of Direct Purchase Information
Request (Indent)
Execution of Orders Click execute button again
Confirmation of Orders Screen of Availability list of

Technical Completion of Orders Materials for Operations will
appears
On This Screen You Will Get

Order wise Materials with Stock
Availability status

BASIC STEPS OF SHUTDOWN Order (For Contractors)
MAINTENANCE PROCESS
Creation of PM03 -Shutdown Go to T. Code ME21N Create
Purchase Order
Orders
Selection of PM03 -Shutdown Select Type of Purchase Order Select from Drop Down
Orders Select from Drop Down

Enter Vendor Code
Report of Shutdown Planning thru Vendors : Purchasing
Creation of Direct Purchase Enter Purchase Organization,

Select from Drop Down
Purchase Group & Company
Order (For Contractors) Code
Go to item overview Tab and Select from Drop Down
Request (Indent)
Enter Account Assignment K
Execution of Orders and Item category - D
Enter Short text of Services
Enter Material Group , Plant , Select from Drop Down.
tracking number (Employee) Search Tracking number
and Department (planner group) thru Vendor by Company
code

MAINTENANCE PROCESS Go to Item Tab and Enter Select from Drop Down
Services number , Qty
Creation of PM03 -Shutdown
Orders Go to Account Assignment Sub Select from Drop Down
Tab and Enter G/L Account
Selection of PM03 -Shutdown number and Cost center
Orders
Report of Shutdown Planning Check entries by Clicking
Button
Order (For Contractors) Correct Entries If error massage
other wise Save the order
Request (Indent) Navigate> SAP Screen
Execution of Orders

4. CONDITION BASE MAINTENANCE PROCESS
BASIC PROCESSES BASIC STEPS OF SHUTDOWN

MAINTENANCE PROCESS
1. Preventive Maintenance Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring Document &
3. Shut down Maintenance Auto Notification
4. Condition base Maintenance Creation of Entry List
Measuring Document Thru Entry list
5. Work shop Repair
Selection of M8 type Notification
6. External Repair/Services Creation of Corrective Maintenance
7. Calibration Order Thru Notification
Execution of Orders

Requisition (For Spare)
MAINTENANCE PROCESS
Creation of PM03 -Shutdown Go to T. code ME51N -Create
Orders PR
Selection of PM03 -Shutdown Enter PR Type & Header note Select from Drop Down
Orders
Account Assignment Type U & Select from Drop Down
Item Category leave Blank
Order (For Contractors) Enter Material & Reqd Qty Select from Drop Down
Creation of Direct Purchase Enter Del date , Plant &

Tracking number (planner Select from Drop Down
Request (Indent)
group)
Execution of Orders
Confirmation of Orders Check entries by Clicking
Button
Correct Entries If error massage
other wise Save the Purchase
request

BASIC STEPS OF CONDITION Creation of Measuring Point
BASE MAINT. PROCESS
Go to T. Code - IK01 -Crete
Creation of Measuring Point
Measuring Point
Creation of Measuring Select Measuring Point Object -
IEQ
Document & Auto notification
Creation of Entry List Select & enter Equipment
Measuring Document Thru number
Entry list Select Relevant Measuring

Selection of M8 type Point Category (Except L & F)
Notification Do not flag MP as counter for
Creation of Corrective CBM
Maintenance Order Thru
Click on Enter Button
Notification
Execution of Orders Write Measuring Position &
Confirmation of Orders Description
Orders

BASIC STEPS OF CONDITION Enter relevant Characteristic

BASE MAINT. PROCESS (UOM & decimal Place
Creation of Measuring Point defaulted)
Selection of Measuring Point Go to Additional data Button

Creation of Measuring header tool bar
Document & Auto notification Enter Upper range limit & Lower
Creation of Entry List range limit
Measuring Document Thru
Entry list
Selection of M8 type Main screen appears. Now click
on Save button to save MP
Notification
Creation of Corrective Navigate> SAP Screen
Notification
Execution of Orders
Orders

BASIC STEPS OF CONDITION Selection of Measuring Point

BASE MAINT. PROCESS
Go to T. Code - IK07 Display
Creation of Measuring Point measuring Point : Measpoint
Selection of Measuring Point Selection
Creation of Measuring Enter Characteristics & MP
Document & Auto notification Category
Creation of Entry List Click Execute Button
Measuring point list appears
Entry list
Selection of M8 type Notification Select relevant Measuring point
Creation of Corrective
Notification
Execution of Orders
Orders

BASIC STEPS OF CONDITION Creation of Measuring
BASE MAINT. PROCESS Document
Go to T. Code IK11 - Crete
Measuring Document
Creation of Measuring
Document & Auto Notification Enter Measuring Point (as
selected)
Creation of Entry List
Measuring Document Thru Again Click on Enter Button
Entry list
Enter MeasRdg as taken from
Selection of M8 type Notification site
Again Click on Enter Button
Notification A Massage Appears In case
Execution of Orders Reading is Outside range
Technical Completion of Again Click on Enter Button
Orders
Main screen of M8 type
Notification Generates
Automatically
BASIC STEPS OF CONDITION Enter Reported by & click Enter
BASE MAINT. PROCESS button
An Auto Notification of M8 type
Selection of Measuring Point Created
A massage comes for
Document & Auto Notification Measuring document Created
Entry list
Selection of M8 type Notification
Notification
Execution of Orders
Orders

BASIC STEPS OF CONDITION Creation of Entry List
BASE MAINT. PROCESS
Go to T. Code IK31 -
Creation of Measuring Point Measuring reading entry list:
Selection of Measuring Point Create
Creation of Measuring Click on Enter Button

Document & Auto notification Screen of Measuring reading
Creation of Entry List entry list: Create Appears
Measuring Document Thru Enter entry list name &
Entry list Description
Selection of M8 type Enter measuring point numbers
Notification As selected from drop down list
Creation of Corrective Click on Enter Button
Maintenance Order Thru All details of Measuring points
Notification Appears in list
Execution of Orders
Now Click on Save Button
Technical Completion of A Massage measurement
Orders reading entry list xxx saved.

BASIC STEPS OF CONDITION Document Thru Entry list
BASE MAINT. PROCESS Go to T. Code IK34
Creation of Measuring Point Collective entry of
Selection of Measuring Point MeasDocuments: Initial screen
Creation of Measuring Enter Entry list number

Document & Auto notification
Measuring Document Thru Collective entry of
MeasDocuments: overview
Entry list screen Appears
Selection of M8 type
Enter measuring Reading in
Notification relevant measuring point field
Notification A Massage Appears In case
Execution of Orders Reading is Outside range &click
Confirmation of Orders again enter button. M8
Technical Completion of Notification will generate
Orders A massage appears as xx Navigate>
Measuring document Created SAP Screen
5. REPAIR MAINTENANCE PROCESS
BASIC PROCESSES BASIC STEPS OF REPAIR

MAINTENANCE PROCESS
1. Preventive Maintenance Creation of M6-Notification
Selection of Order
4. Condition base Maintenance Execution of Orders
6. External Repair/Services Technical Completion of Orders
7. Calibration
Notification

BASIC STEPS OF
Creation of M 6-Notification Notification
Selection of M 6-Notification Enter Notification Type Select from Drill Down
Selection of Order Do not Enter Notification

Number System Generated
Execution of Orders
Confirmation of Orders Click Enter Button
Execution & Completion of Notification Tab Screen Appears
Notification
Enter Notification Description
Enter Code of STD TEXT Select from Drill Down

Attached as per requirement

BASIC STEPS OF Main Work center/ Planner All information Defaulted
MAINTENANCE PROCESSES Group etc Defaulted & can be from equipment master
Creation of M2-Notification Changed If Required
Write Details of Job in Long Text
Selection of Order Go To Location Data Tab
Execution of Orders
Confirmation of Orders Save the Notification
Execution & Completion of Navigate> SAP Screen
Notification
Why-Why Analysis

BASIC STEPS OF Selection of M6 Notification
Creation of M6-Notification Go to T. Code IW28 Selection
of Notification
Creation of PM09-Order Flag check box Outstanding
(as reqd)
Selection of Order
Execution of Orders Enter Notification Date
Select Notification & Create
PM09 Type Order
Notification Click Create button
of Order Tab

Create PM09 Type Order
BASIC STEPS OF
MAINTENANCE PROCESSES Select Relevant Maintenance Select from Drill Down
Creation of M6-Notification Activity Type( Always RVN)
Go to Operation TAB
Selection of Order Select Relevant Work Center Select from Drill Down
Execution of Orders (Type 0001)
Confirmation of Orders Enter Number of Hours

Execution & Completion of Other Field automatically
Populated.
Notification
Select Relevant Work Center for
Operator & Enter Number of
Hours
Go to Component TAB & Attach

Required Material

BASIC STEPS OF
GO to IW38 & Search PM09
Selection of M6-Notification Type Order
Selection of Order
Execution of Orders
Notification

BASIC STEPS OF Release Order & Issue Required
MAINTENANCE PROCESSES Material.
Carry out Repair Work As per
Selection of M6-Notification Request
Selection of Order Navigate> SAP Screen
Execution of Orders
Notification

BASIC STEPS OF
Further process of order will
MAINTENANCE PROCESSES remain same as explained in
Creation of M6-Notification process 1. Preventive
Selection of M6-Notification Maintenance
Creation of PM09-Order Navigate> SAP Screen

Selection of Order
Execution of Orders
Notification

6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC PROCESSES BASIC STEPS OF EXTERNAL REPAIR

MAINTENANCE PROCESS
1. Preventive Maintenance Creation of PM09 Type Order

Selection PMEX Activity type
Creation of Purchase
3. Shut down Maintenance Requisition
4. Condition base Maintenance Creation Of Purchase Order
5. Work shop Repair Confirmation of External
Service Entry Sheet
6. External Repair/Services
7. Calibration

BASIC STEPS OF EXTERNAL Creation of PM09 Type Repair
REPAIR PROCESSES Order
Select Relevant Type Select from Drill Down

Creation of PM09 Type Order Maintenance Activity (Always
RVN, RWN)
Go to Operation TAB
Creation of Purchase Requisition
Select Control Key As PMEX
Creation of Purchase Order
Enter Operation & Select It
Confirmation of External Service
Entry Sheet Click External Service Button
Technical Completion of Orders POP Screen Will Appear Enter Select from Drill Down
Material Group S 524,Purchase
Group, Tracking Number
Enter & GO to External

Processing operation Screen

BASIC STEPS OF Write Short Text of External
MAINTENANCE PROCESSES Service , Approximate Cost of
Repair, Quantity & Unit
Selection PMEX Activity type Write Desired Vendor Code
Enter Cost Element & click Select from Drill Down
Requisition
Creation of Purchase Order Pop Screen of Purchase Select from Drill Down
Confirmation of External Service request Will Appear Enter
Entry Sheet Department (i.e Main Planner
Technical Completion of Orders group)
Go back to Order main screen

Release it & Save Order
Go to Change Mode of Order &

select TAB Actual Data You will
get PR number

BASIC STEPS OF
MAINTENANCE PROCESSES Go To Change Mode of PR
(ME52N)
GO To Document Overview &
Select Relevant PR
Requisition GO TO Customer TAB & Enter
Creation of Purchase Order all Required Deatils
Confirmation of External
Service Entry Sheet Save PR
Orders Navigate> SAP Screen

BASIC STEPS OF
MAINTENANCE PROCESSES MM Will Prepare Purchase Order
on PR

Entry Sheet

BASIC STEPS OF
MM Will Prepare Service Entry Sheet
Creation of PM09 Type Order You will Accept Service Entry Sheet

Entry Sheet

BASIC STEPS OF This Type of Order to be TECO
MAINTENANCE PROCESSES only When FINAL Service Sheet
Made.
Save

Entry Sheet

III. MANAGING REPORTS

STANDARD REPORTS
1. Object Class Statistics [MCI1]
Object breakdown analysis in terms of Maintenance cost
Standard drill down (Key Figure)
Assembly
Construction year
Manufacturer
Material
Object class
Month

STANDARD REPORTS
2. Manufacturer Analysis [MCI2]

Manufacturer wise.
Assembly
Construction year
Manufacturer
Material
Object class
Month

STANDARD REPORTS
3. Location Analysis [MCI3]

Location wise
Assembly
Equipment
Functional Location
Location
Maintenance plant
Planner group
Planning plant
Plant section
Month

STANDARD REPORTS
4. Planner Group Analysis [MCI4]

Planner Group wise
Assembly
Equipment
Functional Location
Location
Maintenance plant
Planner group
Planning plant
Plant section
Month

STANDARD REPORTS
5. Single Object - Damage Analysis [MCI5]
Object Damage analysis in terms of Damage & Causes,

Notification Type wise

Activity code
Cause of damage
CdGrp: damage cause
Code group: activity
Code group: damage
Damage
Equipment
Functional Location
Notification type
Month

STANDARD REPORTS
6. Object Statistics [MCI6]
This report provide the detail about the object statistics ( like
how many Equipment installed on a Function Location)
Object class
Manufacturer
Material
Construction year
Month

STANDARD REPORTS
7. Breakdown Analysis [MCI7]
This report provide the Breakdown Analysis information

(No. of B/D, MTTR, MTBR etc.).
Equipment
Functional Location
Object class
Month

STANDARD REPORTS
8. Cost Analysis [MCI8]
This report provide the Breakdown Analysis information

( No. of B/D, MTTR, MTBR etc.).
Equipment
Functional Location
Object class
Month

STANDARD REPORTS
9. MTTR/MTBR Equipment [MCJB]
This report provide :
MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR

etc.).
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)

STANDARD REPORTS
10. MTTR/MTBR Functional Location [MCJC]
This report provide :
MTTR/MTBR Analysis Equipment wise

( No. of B/D, MTTR, MTBR etc.)
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)

6.2 LIST OF DEVELOPED REPORTS

LIST OF DEVELOPED REPORTS:
S. The
No. following
PLANT REPORTS
are the Reports that are being developed in SAP:
1 List of Damage & Cause - Summary Report (Equipment wise)
2 Breakdown Matrix - Equipment ABC indicator & breakdown category wise
3 Work Center / Equipment wise Material Consumption
4 Equipment Schedule Maintenance Report
5 Breakdown why-why Analysis Report

6 PM order Skipped / Rescheduled Report
7 PM Order Slippage Summary Report ( Schedule Maintenance Slippage in

Plant VC)
8 Preventive Maintenance Work Request Report
9 Motor Failure Report
10 Inspection Check List

S. No. PLANT REPORTS

11 Maintenance Order / Operation Pending List
12 Section / Equipment Performance Report
13 Equipment Lubrication Consumption Report
14 Quarterly Lubrication Consumption Report
15 Purchase Request Tracking Report
16 Equipment Maintenance Cost Report
17 List of Service Entry Sheets
18 Work Center Wise Service Cost Report
19 Shutdown (consolidated) Planning Report (resources & cost)

S.No. MINES REPORTS

20 Tyre Life Summary Report
21 Equipment Position Wise Tyre Run Report
22 Tyre Maintenance Register
23 Oil Consumption Report
24 Oil, Filter & Lubricant Monitoring Report
25 Assembly Life Details
26 Sub assembly Performance Report
27 Breakdown Summary

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1
Crete Measuring Point- IK01

Measuring Point Object

Select Equipment

Select Relevant Measuring Point Category
Flag for Measuring Point as a Counter
Write Measuring Position Description
Write Description of Measuring Point
Select From Drop

Down ,Always use
Attach Relevant CHARACTERISTICS RUNNINGHOURS

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2
Press Enter ICON
Maximum Reading of
Enter Counter Over Flow Reading
Counter
Enter Annual Estimate Reading It Will be drive Plan
Press ICON For Save
Message : Measuring Point . Created
THE END

CREATION OF MESURING POINT (LUB/Diesel Consumption) Sheet 1/2


Select Equipment
Always Select Category

L- for Lubrication &
Select Relevant Measuring Point Category F- Fuel Consumption
Flag for Measuring Point as a Counter
Select From Drop

Down , ,Always LUB
Attach Relevant CHARACTERISTICS CONCOSUMPTION..

CREATION OF MESURING POINT(LUB/Diesel Consumption) Sheet 2/2
Press Enter ICON
Dont Enter Counter Over Flow Reading & Annual

Estimate Reading
Enter Save ICON Button
Message : Measuring Point ..Created
Press ICON

Estimate Reading

The END

CREATION OF MESURING POINT Sheet 1/2


Select Equipment

Select Relevant Measuring Point Category
Press Icon
Select From Drop

Attach Relevant CHARACTERISTICS Down

CREATION OF MESURING POINT Sheet 2/2
Press Enter ICON

Estimate Reading
Press ICON

Estimate Reading

THE END

CREATION OF MESURING POINT DOCUMENT (IK11)
Creation of Measuring Document IK11

Select Desired Measuring Point
Enter ICON Button Next Screen will Appear

for entering Reading
Counter should be
GREATER than
Enter Counter Reading or Difference of Counter Previous Reading or
Difference not more
than 24 Hours
Press ICON Button For Save
Message : Measuring Document ..Created.
THE END

MAINTENANCE ITEM Continued..
WITH
TIME BASED PACKAGE

CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04
Create Maintenance Item IP04

Maintenance Plan Category
Maintenance Strategy Select from Drop Down,

Use Always GILDAY &
GILMON Only
Write Maintenance Item Description

Enter Equipment
This will be PM01

Write ORDER Type
Always

Maintenance Activity Type (Use PVM Or AMC )
Attach Relevant Task List

CREATEING MAINTENANCE ITEM (TIME BASE) Sheet -2/2
For Selection of Task List Use Icon
Task List Display Screen will Appear on Screen
Flag General Task List
Press Icon , Screen will appear with List of Task

Lists
Select Appropriate Task List
Press Icon Enter
Press Icon for Save
You will get Message : Maintenance Item ( System

Generated Number) Created. THE END

MAINTENANCE ITEM
WITH
PERFORMANCE BASED PACKAGE

CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2
Create Maintenance Item IP04

Maintenance Plan Category
ALWAYS Use PERFHR

For Plant,TPP,DG
Maintenance Strategy Equipment & MINHR
For Mines Equipment
Write Maintenance Item Description

Enter Equipment
This will be PM01

Write ORDER Type
Always

Maintenance Activity Type
Attach Relevant Task List

CREATE MAINTENANCE ITEM (PERFORMANCE BASE )Sheet -2/2
For Selection of Task List Use Button
Task List Display Screen will Appear on Screen
Flag General Task List
Press Button , Screen will appear with Task List
Select Appropriate Task List
Press Icon
Press Icon for Save
You will get Message : Maintenance Item ( System

Generated Number) Created
THE END

Creation of Maintenance Item-[IP04]

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3 IP01
Create Maintenance Plan (IP01)
Maintenance Plan Number is System Generated

Number
Maintenance Category
Select from Drop

Down ,Always Use
Maintenance Strategy GILDAY & GILMON
Press Icon
Write Maintenance Plan Short Description
Go to TAB For Assigning Maintenance Item
POP Screen will appear

Message : Possible Deletion of Data Entered When
Selecting
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 2/3
Display Maintenance Item :Selection Criteria Screen

Will Appear ,Write Equipment Number & Press Icon
Main Planner Group ,Main Work Center & other field

automatically Populated from Equipment Master

automatically Populated

Press Icon
Go to TAB Maintenance Plan Scheduling

Parameter
Write Scheduling Period :365 Days
Flag Fro Completion Requirement

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 3/3
Press Icon For Save
Pop Screen Will Appear For START DATE
Select Radio Button NO
Press Icon
Message will Appear on Screen : Maintenance Plan

.Created
The End

CREATION OF MAINTENANCE PLAN (PERFORMANCE BASE) Sheet 1/3
Create Maintenance Plan (IP01)
Maintenance Plan Number is System Generated

Number
Maintenance Category
Select from Drop
Down ,Always Select
PERFHR For Plant,
Maintenance Strategy DG, TPP & MINHR
For Mines
Press Icon
Write Maintenance Plan Short Description & Enter

Counter
Go to TAB For Assigning Maintenance Item
POP Screen will appear

Message : Possible Deletion of Data Entered When
Selecting
CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 2/3
Display Maintenance Item :Selection Criteria Screen

Will Appear ,Write Equipment Number & Press Icon


automatically Populated

Press Icon
Go to TAB Maintenance Plan Scheduling

Parameter
Write Scheduling Period :365 Days
Flag For Completion Requirement

CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 3/3
Press Icon For Save
Pop Screen Will Appear For START Counter

Reading
Select Radio Button NO
Press Icon
Message will Appear on Screen : Maintenance Plan

.Created
The End

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PLANT MAINTENANCE SYSTEM

2 Presentation Title | Confidential | Document ID | Dec 16, 2017

3 Presentation Title | Confidential | Document ID | Dec 16, 2017

4 Presentation Title | Confidential | Document ID | Dec 16, 2017

BASIC MASTERS CONTENTS OF MAINTENANCE

5 Presentation Title | Confidential | Document ID | Dec 16, 2017

BASIC MASTERS CONTENTS OF MAINTENANCE

6 Presentation Title | Confidential | Document ID | Dec 16, 2017

Functional locations Structure is a hierarchical Presentation of a Tech.

Manage individual data from a maintenance perspective for the object

7 Presentation Title | Confidential | Document ID | Dec 16, 2017

8 Presentation Title | Confidential | Document ID | Dec 16, 2017

BASIC MASTERS CONTENTS OF FUNCTIONAL

9 Presentation Title | Confidential | Document ID | Dec 16, 2017

C Colony Functional Locations

10 Presentation Title | Confidential | Document ID | Dec 16, 2017

Display of Function Location-[IL03]

List Editing of Function Location-[IH06]

Display ( Multi Level) Function Location[IL07]

11 Presentation Title | Confidential | Document ID | Dec 16, 2017

BASIC MASTERS BASIC CONTENTS OF MAINTENANCE

1. Functional Locations Equipment Category

12 Presentation Title | Confidential | Document ID | Dec 16, 2017

Defining Equipment Categories is a facility in SAP/PM to

13 Presentation Title | Confidential | Document ID | Dec 16, 2017

CATEGO EQUIPMENT EXAMPLES

C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS

14 Presentation Title | Confidential | Document ID | Dec 16, 2017

CATEGOR EQUIPMENT EXAMPLES

P PROCESS EQUIPMENTS CYCLONES/HOPPERS

Q QC TEST EQUIPMENTS CUBE TESTING MACHINE /

R PRODUCTION RESOURCES/TOOLS CRANES

T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER

U UTILITY EQUIPMENTS COMPRESSOR/WATER PUMPS

15 Presentation Title | Confidential | Document ID | Dec 16, 2017

C Civil Objects & General Equipt. 80000000 89999999

16 Presentation Title | Confidential | Document ID | Dec 16, 2017

Technical Object Types are the logical grouping of Objects on the

ME_GEARBOX Gear Box

EL_MOTORS Electrical Motors

17 Presentation Title | Confidential | Document ID | Dec 16, 2017

Plant in which maintenance tasks are planned and executed. In GIL ,

18 Presentation Title | Confidential | Document ID | Dec 16, 2017

19 Presentation Title | Confidential | Document ID | Dec 16, 2017

Plant Section is a division of Maintenance Plants into Production

Plant Category Description

20 Presentation Title | Confidential | Document ID | Dec 16, 2017

Planner Group defines the Group of People (Employees) responsible

PLANNER GROUP CODIFICATION LOGIC

PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION

MCM = Mechanical + Cement Mill

21 Presentation Title | Confidential | Document ID | Dec 16, 2017

Cost Center Concept as applied in GIL :

Mechanical Electrical Instrumentation Process

22 Presentation Title | Confidential | Document ID | Dec 16, 2017

Display of Usage List

23 Presentation Title | Confidential | Document ID | Dec 16, 2017

BASIC MASTERS BASIC CONTENTS OF CLASS &

24 Presentation Title | Confidential | Document ID | Dec 16, 2017

Logical Grouping of Equipments having Similar Functions.