pm module ppt
DESCRIPTION
Write me feedback@ facebook, for any SAP PM or ABAP document help.TRANSCRIPT
Click to edit Master title style
“Your Trusted IT Partner”
Process Excellence
SAP PLANT MAINTENANCE
Click to edit Master title styleSAP R/3 ERP
Accounting Area Financial accounting (FI) Controlling (CO) Asset Accounting (FI AA)• Human Resources HR• LogisticsProduction Planning (PP)Materials Management (MM)Sales and Distribution (SD)Quality Management (QM)Service Management (SM)Plant Maintenance (PM)
Click to edit Master title styleSAP Organizational Structure
Click to edit Master title stylePM Overview
Plant Maintenance Introduction Plant Maintenance OrganizationTechnical ObjectsBreak Down MaintenanceCorrective MaintenanceRefurbishment Of Spare PartsPreventive MaintenanceWork Clearance Management
Click to edit Master title stylePlant Maintenance Introduction
SAP Plant Maintenance automates the process of performing facility repair and maintenance requests.
For example,. SAP records a problem that is reported, labor and materials are planned, costs are recorded, and then costs are settled
Plant Maintenance operates the overall maintenance business processes and functions allows a maintenance organization to:
Identify, document, and correct failures and degradations of any assets for which they have responsibility.
Click to edit Master title stylePlant Maintenance Process Flow
Click to edit Master title stylePlant Maintenance Process Flow
PM Process Flow
Maintenance Order
Notification
Plan
Control
Complete
Schedule
Execute
Click to edit Master title stylePlant Maintenance Process Overview
Click to edit Master title stylePlant Maintenance Organization
Plant Maintenance Organization1) Overview of Processes and Available Solutions
Lifecycle of technical Asset• Investment Planning• Projects Definition• Selection of Vendor• Plant Maintenance• External Procurement• shutdown
Click to edit Master title stylePlant Maintenance Organization
Plant Maintenance OrganizationCharacteristics
Classes
Equipment/Functional Locations
Tasks List
Bill of Material
Maintenance Work Centers
Cost Center
Cost Records
MaintenanceStrategies
Maintenance Plans
Purchase Order/Release Order
Master Data
Planning
Order ProcessingPurchase Requisition
Time Conformation
Capacity Load
Maintenance Order
Material Issue
Material Reservation
Maintenance Notifications
Goods Receipt/Invoice Receipt
Click to edit Master title stylePlant Maintenance Organization
2) User InterfaceVarious methods that user connects to SAP Power User Sporadic User
3) Organizational Levels In Plant Maintenance Depending on the Company Structure
Maintenance planning is either of following type
• Plant-Based (Decentralized)• Cross-Plant (Centralized)
Click to edit Master title stylePlant Maintenance Organization
3) Organizational Levels In Plant Maintenance
Analyze Existing Company StructureDefine Maintenance Plants/Planning PlantsAssign Planning Plant/Work Center Maintenance planner groups are assigned to planning
plantsMaintenance work centers are assigned to
maintenance plant
Click to edit Master title stylePlant Based Organization Structure
Plant Based Organizational Structure
Click to edit Master title stylePlant Maintenance Organization
Maintenance Plant & Planning Plant The plant, at which the operational systems of a
company are installed, is called the maintenance plant.
If the maintenance work is planned at this plant, the maintenance plant is also the maintenance planning plant.
A maintenance planning plant is the organizational unit in which maintenance requirements are planned.
Click to edit Master title stylePlant Maintenance Organization
Maintenance Planning Plant Structure
Click to edit Master title stylePlant Maintenance Organization
Planner Group The planners within a maintenance planning plant
are defined by maintenance planner groups.
The units of capacity in Plant Maintenance are managed as maintenance work centres in the PM system.
The maintenance work centres are usually assigned to the maintenance planning plant.
Click to edit Master title styleWork Centers
Work center is an organizational unit where work is carried out.Ex: Machine, Group of machines or group of persons.
Work centres belong to the master data in PM and provide the capacity required to perform a task.
The basic data contains general data such as work centre category, description, responsibility, and usage
Work centers can be linked to: Cost Centers, Positions, People
Click to edit Master title styleWork Centers
Functions: Costing : To determine the costs of an internal
activity by a product unit Scheduling : To determine the dates when
operations should be performed. Capacity Planning : The capacity requirements for
the operations in the orders are determined
Click to edit Master title styleTechnical Objects
Technical Objects1) Functional Locations Functional locations are elements of a technical structure . We create
Functional Structures if we want to represent systems or operational structures within our company according to functionality.
Create functional locations hierarchically, and can also structure them based on the following criteria:
Spatial Ex: Buildings. Technical Ex: Press or Press Hydraulics Process-related Ex: Polymerization,.
Click to edit Master title styleFunctional Location Creation
Click to edit Master title style
Functional Locations
Functional Location Structure
Click to edit Master title style
Functional Locations
The main Aim of creating Functional Locations is to Structure a technical System or building into units that are relevant to Plant maintenance.
Functional Location Structure
Click to edit Master title styleFunctional Location
Structure Indicator The identification for functional locations is created using the structure indicator. The structureindicator consists of two input fields:
Edit mask : The edit mask is used to control which characters may be used for identification (letters, numbers, or both) and how these characters are grouped together or split.
Hierarchy levels: The hierarchy levels are used to define which level ends at which character and how many hierarchy levels the structure may contain.
Click to edit Master title style
Functional LocationsA functional location can be identified using a maximum of 40 characters (= maximum length of the edit mask).
Functional Location Structure
Click to edit Master title styleEquipment
2) Equipment A piece of equipment could be part of bigger
technical structures or independent Piece of equipment is usually represented as single
object(Ex: Pumps, motors, vehicle) for which maintenance tasks should be performed.
Click to edit Master title styleEquipment
Create an equipment master record for a technical object if: You need to manage individual data for the object
Breakdown, prepared or preventive maintenance task are required for an object and must be recorded
Technical data for this object must be collected and evaluated over long periods of time
The costs of maintenance tasks for this object are to be monitored
Record the usage time of this object at functional locations
Click to edit Master title style
Functional LocationsThe time-based data can be used to monitor a piece of equipment dynamically, that is, track changes to the equipment over a specific period of time.
Purpose of Equipment
Click to edit Master title styleEquipment
2) Equipment This role contains all the functions that you require to
process equipment.Equipment Activities in Plant Maintenance (PM) Creating a piece of equipment (generally, as
production resource/tool, fleet object) Collective entry for equipment Changing a piece of equipment Data transfer from equipment Taking up data transfer
Click to edit Master title style
Functional Locations
Bills of material are used for different purposes. The usage depends on the enterprise area
Bill Of Material
Click to edit Master title styleBill Of Material
3) BOM The Production Bill of Materials represents a
finished product (parent )made up of different inventory components (children). During the production process, you turn the components into the finished product.
Components in the production bill of materials are physical items (for example a screw, a wooden board, a measured quantity of lubricant or paint), or virtual objects (one work hour)
Click to edit Master title styleBill Of Material
3) BOM The engineering/design bill of material includes all
the elements of the product (from an engineering viewpoint) and contains the technical data. It is usually not dependent on the order.
The costing bill of material reproduces the product structure and forms the basis for automatic determination of the material usage costs for a product. Items that are not relevant for costing are not included in this bill of material.
Click to edit Master title styleBill Of Material
3)BOM The maintenance bill of material has three important
functions: It only contains items relevant to Plant Maintenance.
Structuring of the object : The structure of an object should be displayed as clearly as possible from a maintenance viewpoint.
Spare parts planning in the order: If a bill of material exists for a technical object, it can be used during the planning process of a maintenance order for the purpose of spare parts identification and planning.
Spare parts planning in the task list: Spare parts can be planned in the task list based on a bill of material
Click to edit Master title styleBill Of Material
3)BOM Instead of a uniform bill of material, these areas use
"their own" bill of material with area-specific data (for example, production).
They only evaluate bills of material containing area-specific data. This results in a targeted bill of material explosion, whereby only the area-specific data is made available.
Click to edit Master title styleBill Of Material
3) BOM Categories of BOM’s are
Material BOM Equipment BOM Functional Location BOM A material BOM is a bill of material that is first
created for a material independently of a technical object. To do this, material creation is must.
Create a material BOM for the material
Click to edit Master title style
Functional Locations
Bill Of Material
Click to edit Master title styleBreak Down Maintenance
Break Down Maintenance Using this business process we can report, perform,
and document maintenance tasks that arise suddenly. All the resources used, costs, and technical details of
the maintenance task are recorded centrally and can then be evaluated.
Usually this process is relevant if a technical asset exhibits a defect, for example, if a pump is leaking or a printer is not printing properly.
Click to edit Master title styleBreak Down Maintenance
Diverse employees can create a maintenance notification to report the defect.
The responsible maintenance technician receives these notifications in his or her work list and makes the necessary repairs. Process Flow1.Notification & Scheduling2. Execution3. Completion
Click to edit Master title style
Break Down Maintenance
Break Down Maintenance Flow
Break Down Maintenance
Click to edit Master title styleBreak Down Maintenance
Create / process notification Generate work list for notifications Create / process order Confirm time Modify technical object structure Process Execution complete order
Click to edit Master title styleRefurbishment Of Spare Parts
Refurbishment of spare parts: In a company ,Defective or warn-out spare parts in storage
should be refurbished.
Refurbishment Process Pre Requisites for Refurbishment in Material Master Separate Evaluation Refurbishment Order Check the effects of refurbishments on stock value
Click to edit Master title style
Break Down Maintenance
Refurbishment Process
Click to edit Master title styleRefurbishment Of Spare Parts
Refurbishment of spare parts: During the refurbishment process, equipment is
maintained by a team of maintenance planners, maintenance technicians, and store persons.
After a maintenance technician has determined and replaced the defective equipment, the maintenance planner posts the defective item to stock
After planning has been posted, the maintenance planner creates and releases a refurbishment order for the given items.
Click to edit Master title styleRefurbishment Of Spare Parts
Refurbishment of spare parts: Calculated the time and material resources are neede
for the refurbishment. The order is conformed and Completed.
The stock value changes dynamically according to the condition of the items, with the price of a refurbished item covering all internal and external material and labour costs spent on refurbishing.
Click to edit Master title stylePreventive Maintenance
Preventive Maintenance Preventive maintenance work is performed to ensure
optimal operation of equipment & avoid costly unplanned equipment failure or shutdown.
To keep down times and maintenance costs minimum, the technical systems are inspected and maintained regularly
Preventive Maintenance Can be followed by 3 Factors Time Based Performance Based Condition based
Click to edit Master title stylePreventive Maintenance
Preventive Maintenance Time Based In time-based preventive maintenance, the
maintenance tasks are planned and performed depending on the time-dependent intervals determined. (Ex ,Every 6 months)
Performance-Based (Performance) This preventive maintenance, tasks are triggered
after a specific performance level has been reached(Ex, Every 10,000 kms)
Click to edit Master title stylePreventive Maintenance
Preventive Maintenance Condition Based
If the service life is exhausted or if the asset is no longer in good enough condition to perform its service to the required quality
Then the service life must be restored through maintenance or repair work. These maintenance tasks are generated and performed based on a certain asset condition.
Click to edit Master title style
Break Down Maintenance
Preventive Maintenance
Preventive Maintenance
Click to edit Master title stylePreventive Maintenance
Task Lists In the company, all inspection and maintenance tasks
that must be performed at regular intervals are defined in maintenance task lists. Task list header data
Maintenance Planning Single Cycle Plan (Same activity at regular
intervals) Strategy (Maintenance work performed in
different cycles)Maintenance strategy
Click to edit Master title stylePreventive Maintenance
Preventive Maintenance Process in Detail Create / process notification Generate work list for notifications Create / process order Plan and schedule order Perform work clearance management Confirm time Perform evaluations in plant maintenance information
system (PMIS)
Click to edit Master title styleCorrective Maintenance
Corrective Maintenance Maintenance actions carried out to restore a defective
item to a specified condition
5 Phases of corrective Maintenance Entering Requirement(Notification) Planning Orders with Operations and Materials (Planning) Monitoring the cost (Control) Performing the tasks(Execution) Completing the Order and Notifications.(Completion)
Click to edit Master title style
Break Down Maintenance
Corrective Maintenance
Corrective Maintenance
Click to edit Master title style
ACTIVITIES are work performed for Notifications.Importent for inspection, they prove that certain tasks have been performed.TASKS: Describes the Activities that still have to be performed.(Also used for planning purpose)
Corrective Maintenance
Corrective Maintenance
Click to edit Master title styleCorrective Maintenance
Corrective Maintenance5 Phases of corrective Maintenance
Entering Requirement(Notification) Planning Orders with Operations and Materials
(Planning) Monitoring the cost (Control) Performing the tasks(Execution) Completing the Order and Notifications.
(Completion)
Click to edit Master title styleCorrective Maintenance
Corrective Maintenance Notification: is the technical object contains the
description about the malfunction or requirement Malfunctions and other requirements are recorded in
notification, notifications can be accessed and processed via a list
Planning : In this phase orders are created and planned on the basis of the reported requirements. Planning compasses the Work to be performed , and the material required.
Click to edit Master title styleCorrective Maintenance
Corrective Maintenance Control: In this phase order runs through the different
phases such as material availability check, capacity planning.
Execution: Order is executed in this phase, Required material for the order is withdrawn.
Completion: Technical Conformation and Technical completion.
Click to edit Master title styleWork Clearance Management
Work Clearance Management This business process to enforce all safety measures
that must be enforced before inspections, repairs, or preventive maintenance work are performed.
Maintenance Workers operate in a dangerous Environment(Ex: High Voltage, Radio Activity).
The WCM component helps company to control and monitor safety measures.
Helps to ensure and secure working conditions for plant maintenance employees.
Click to edit Master title style
Break Down Maintenance
Work Clearance Management
Work Clearance Management
Work Clearance Management is integrated into the Plant Maintenance (PM) component
Click to edit Master title style
Break Down Maintenance
WCM Process Flow (1)
Work Clearance Management
Order
Work Clearance Application
Work ClearanceDocument
Work ClearanceDocument
Create Order
Plan Order/ Request Tag Out
Specify Object containing Tag out/Lockout
Approve and Perform Tag out/Lockout
Click to edit Master title styleWork Clearance Management
Work Clearance Management Lockout-Tag out (LOTO) or lock and tag is a safety
procedure which is used to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work
Work Clearance Document: This document contains a detailed description of lockout / tag out .
Click to edit Master title style
Break Down Maintenance
WCM Process Flow (2)
Work Clearance Management
Release Order
Work Clearance Application
Work ClearanceDocument
Order Completion
Release Order Determined
Completing Tagging
Perform Un-tagging
Technically Completing Order
Click to edit Master title style
QUERIES ?
Click to edit Master title style
THANK YOU