SAP Plant Maintenance

Purpose: to begin understanding of SAP Plant Maintenance module

October 24, 2007 © 2006 IBM Corporation

 Maintenance Management in SAP R/3

SD FI
Sales & Financial
Distribution Accounting
MM CO
Materials Controlling
Mgmt.
PP AM

R/3
Production Fixed Assets
Planning Mgmt.

QM
Quality
Client / Server PS
Project
Mgmt.
PM ABAP/4 WF
System

Plant Workflow
Maintenance
HR IS
Human Industry
Resources Solutions

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Plant Maintenance Organizational Elements

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
SAP Plant Maintenance Organizational Elements

Master Data
Prev Maintenance

Work Order
Management

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
SAP Plant Maintenance Organizational Elements
Master Data
Classification Bill of Materials
Equipment
Task List Workcenter
Master
Planner Group
Measurements
Functional Location

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
SAP Plant Maintenance Organizational Elements
Master Data
Classification Bill of Materials
Equipment
Task List Workcenter
Master
Planner Group
Measurements
Functional Location

Notification

Work
Order
Work Order
Planning Management
Scheduling
& Execution

Report Report Material

History Labor Acquisition

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
SAP Plant Maintenance Organizational Elements
Prev Maintenance Master Data
Classification Bill of Materials
Maintenance Equipment
Strategy Plans and Task List Workcenter
Master
Items Planner Group
Measurements
Scheduling Functional Location

Notification

Work
Order
Work Order
Planning Management
Scheduling
& Execution

Report Report Material

History Labor Acquisition

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
SAP Plant Maintenance Organizational Elements
Prev Maintenance Master Data
Classification Bill of Materials
Maintenance Equipment
Strategy Plans and Task List Workcenter
Master
Items Planner Group
Measurements
Scheduling Functional Location

Notification

Work
Order
Work Order
Planning Management
Scheduling
& Execution

Report Report Material

History Labor Acquisition

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
 PM/PS Business Process Diagram
High Level Business Process

Operations - Overview of Work Order Management Business Processes using

the SAP Plant Maintenance and Project Systems Modules

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Operations - Overview of Work Order Management Business Processes using the SAP Plant Maintenance and Project Systems Modules

Is repair or
Trigger

Need for Repair, New Capital installation to be

No No
Equipment, New Expenditure? charged to a work
Construction, or Material order?
identified

Yes
Capital Project

No Cancel or Resubmit
MD
Yes
Request Approval Request New
Included in Prepare Prepare Project Equipment Complete/
for unbudgeted Prepare Budget Prepare Detail Master Data
No current Capital Yes Preliminary Design Definition and Route for Approval Approved? Purchase Either Close WBS
Capital and Spending Plan Design Package to be set up
Budget? Package WBS Structure Only? Project
Expenditure or maintained
No

Yes
for Services Send PO/release to Contractor
Management

Services Create
Create
Materials

Purchase Capital
Purchase Order
No Requisition Receive Material Purchase Yes Issue material to Capital Project As Required
Only?
Material
Materials No
in Stock?
Yes Issue material to Work Order

Yes
Work Order

Complete/
Cancel or Order Approved Order Pending
INSP Create Notification Create Order No Yes Release Order Close Work
Resubmit for Execution? in Backlog
Order

No
Planning

Plan Order Are

(labor, material, materials or
contractor Contract Services
services) required?
Schedule and
Execution

Necessary
Dispatch Work to Schedule Work to materials,
Perform Work Print Shop Papers Yes
Crew be Performed contractors, tools,
etc available?

No
Completion

Order
Report Labor Report History Record Contractor
Replenishment Maintain
Hours Codes Service Usage
Material Master Data
and Preventive
Maintenance
Master Data

Create/Maintain Automatic Creation of

MD Create/Maintain Create/Maintain Create/Maintain Create/Maintain Maintenance Plan Schedule
Functional Inspection or Preventive INSP
Equipment Master Bill of Materials Task Lists (inspection, preventive maintenance) Maintenance Plan
Location Maintenance Notifications

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Operations - Overview of Work Order Management Business Processes using the SAP Plant Maintenance and Project Systems Modules

Is repair or

Repair
Trigger

Need for Repair, New Capital installation to be

No No
Equipment, New Expenditure? charged to a work
Construction, or Material order?
identified

Yes
Capital Project

No Cancel or Resubmit
MD
Yes
Request Approval Request New
Included in Prepare Prepare Project Equipment Complete/
for unbudgeted Prepare Budget Prepare Detail Master Data
No current Capital Yes Preliminary Design Definition and Route for Approval Approved? Purchase Either Close WBS
Capital and Spending Plan Design Package to be set up
Budget? Package WBS Structure Only? Project
Expenditure or maintained
No

Yes
for Services Send PO/release to Contractor
Management

Services Create
Create
Materials

Purchase Capital
Purchase Order
No Requisition Receive Material Purchase Yes Issue material to Capital Project As Required
Only?
Material
Materials No
in Stock?
Yes Issue material to Work Order

Yes
Work Order

Complete/
Cancel or Order Approved Order Pending
INSP Create Notification Create Order No Yes Release Order Close Work
Resubmit for Execution? in Backlog
Order

No
Planning

Plan Order Are

(labor, material, materials or
contractor Contract Services
services) required?
Schedule and
Execution

Necessary
Dispatch Work to Schedule Work to materials,
Perform Work Print Shop Papers Yes
Crew be Performed contractors, tools,
etc available?

No
Completion

Order
Report Labor Report History Record Contractor
Replenishment Maintain
Hours Codes Service Usage
Material Master Data
and Preventive
Maintenance
Master Data

Create/Maintain Automatic Creation of

MD Create/Maintain Create/Maintain Create/Maintain Create/Maintain Maintenance Plan Schedule
Functional Inspection or Preventive INSP
Equipment Master Bill of Materials Task Lists (inspection, preventive maintenance) Maintenance Plan
Location Maintenance Notifications

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Operations - Overview of Work Order Management Business Processes using the SAP Plant Maintenance and Project Systems Modules

Is repair or

Repair with Materials/Services

Trigger

Need for Repair, New Capital installation to be

No No
Equipment, New Expenditure? charged to a work
Construction, or Material order?
identified

Yes
Capital Project

No Cancel or Resubmit
MD
Yes
Request Approval Request New
Included in Prepare Prepare Project Equipment Complete/
for unbudgeted Prepare Budget Prepare Detail Master Data
No current Capital Yes Preliminary Design Definition and Route for Approval Approved? Purchase Either Close WBS
Capital and Spending Plan Design Package to be set up
Budget? Package WBS Structure Only? Project
Expenditure or maintained
No

Yes
for Services Send PO/release to Contractor
Management

Services Create
Create
Materials

Purchase Capital
Purchase Order
No Requisition Receive Material Purchase Yes Issue material to Capital Project As Required
Only?
Material
Materials No
in Stock?
Yes Issue material to Work Order

Yes
Work Order

Complete/
Cancel or Order Approved Order Pending
INSP Create Notification Create Order No Yes Release Order Close Work
Resubmit for Execution? in Backlog
Order

No
Planning

Plan Order Are

(labor, material, materials or
contractor Contract Services
services) required?
Schedule and
Execution

Necessary
Dispatch Work to Schedule Work to materials,
Perform Work Print Shop Papers Yes
Crew be Performed contractors, tools,
etc available?

No
Completion

Order
Report Labor Report History Record Contractor
Replenishment Maintain
Hours Codes Service Usage
Material Master Data
and Preventive
Maintenance
Master Data

Create/Maintain Automatic Creation of

MD Create/Maintain Create/Maintain Create/Maintain Create/Maintain Maintenance Plan Schedule
Functional Inspection or Preventive INSP
Equipment Master Bill of Materials Task Lists (inspection, preventive maintenance) Maintenance Plan
Location Maintenance Notifications

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Operations - Overview of Work Order Management Business Processes using the SAP Plant Maintenance and Project Systems Modules

Is repair or

Capital
Trigger

Need for Repair, New Capital installation to be

No No
Equipment, New Expenditure? charged to a work
Construction, or Material order?
identified

Yes
Capital Project

No Cancel or Resubmit
MD
Yes
Request Approval Request New
Included in Prepare Prepare Project Equipment Complete/
for unbudgeted Prepare Budget Prepare Detail Master Data
No current Capital Yes Preliminary Design Definition and Route for Approval Approved? Purchase Either Close WBS
Capital and Spending Plan Design Package to be set up
Budget? Package WBS Structure Only? Project
Expenditure or maintained
No

Yes
for Services Send PO/release to Contractor
Management

Services Create
Create
Materials

Purchase Capital
Purchase Order
No Requisition Receive Material Purchase Yes Issue material to Capital Project As Required
Only?
Material
Materials No
in Stock?
Yes Issue material to Work Order

Yes
Work Order

Complete/
Cancel or Order Approved Order Pending
INSP Create Notification Create Order No Yes Release Order Close Work
Resubmit for Execution? in Backlog
Order

No
Planning

Plan Order Are

(labor, material, materials or
contractor Contract Services
services) required?
Schedule and
Execution

Necessary
Dispatch Work to Schedule Work to materials,
Perform Work Print Shop Papers Yes
Crew be Performed contractors, tools,
etc available?

No
Completion

Order
Report Labor Report History Record Contractor
Replenishment Maintain
Hours Codes Service Usage
Material Master Data
and Preventive
Maintenance
Master Data

Create/Maintain Automatic Creation of

MD Create/Maintain Create/Maintain Create/Maintain Create/Maintain Maintenance Plan Schedule
Functional Inspection or Preventive INSP
Equipment Master Bill of Materials Task Lists (inspection, preventive maintenance) Maintenance Plan
Location Maintenance Notifications

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Design Considerations for a Work Order Management System

 Treatment and design of capital and expense work orders.

 Conversion of history and the format will it be stored.
 Set-up of Preventive Maintenance to auto-generate released work orders vs.
having a planner review the orders prior to releasing the orders.
 Use of detailed scheduling of work orders and individuals.
 Skills tracking and how the information is used in planning work.
 Collection of information surrounding breakdowns, reason codes, failure
information, etc.
 Culture changes necessary to move from a primarily manual work
management tool to an automated system.
 Design of the process by which work order planning, scheduling, releasing,
and completing work orders will be handled.
 Design of the master data (equipment and functional locations) so that the
business goals can be achieved without hampering the daily operations.

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
 PM and FICO Relationship

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation
Relationship between Plant Maintenance and FI/CO
FI/CO Plant Maintenance FI/CO
Cost
Center

Functional Location Structure

Hierarchy
Cost Center

Cost Center (who pays for

Class and Characteristics

Class and Characteristics

“Receiving”
• gl

Object Part Codes

Overheads, etc

• Activity types

Damage Codes
Planner Group
• etc

Activity Codes
Cost Center

Cause Codes
Manufacturer
WorkCenter
Benefits

“Producing” PS
Payroll

Repairs)

Model
• gl WBS
• Activity types
• etc Project
Functional Equipment History
Activity Work Location Master Codes
Types Center
• gl
• $ per Hour Work Order
Value Categories Internal
$ per Hour times Labor Hours $$ Labor, Internal .......Group of gl’s
Settlement Order
Labor, External .......Group of gl’s
$$ Material, Internal ... Group of gl’s
Material, External ... Group of gl’s
$$ Misc ................. Group of gl’s

Materials
Purchase
Inventory • gl – internal material Orders Other….

• gl – spare parts
MRP / • gl – supplies
Purchase • gl – services
• gl …… etc
Order

Verizon Fleet Management – Planning Meeting October 24, 2006 © 2006 IBM Corporation