sap plant maintenance

Presentation By:

Mr. Subhrajyoti Bhattacharjee

B.E., P.G.D.M., PMP®, Certified SAP PM Solution

Consultant

SAP Plant Maintenance

Brief Background of Presenter Subhra works as SAP Systems Analyst at Iluka

Resources Limited, Perth, Western Australia

He has a Net experience of around 7.8 years with around6 years of SAP Consulting Experience in SAP PM & CS,MM modules. He has also has standard configurationknowledge of SAP PS, DMS and integration aspects ofother SAP modules & applications

He has worked in multiple SAP Implementation, Upgrade,Support & Audit assignments in Australia, USA, India andMiddle East and is an ex-employee of PwC India Ltd,T.C.S. Limited

He also possesses Core Industry experience of 1.8 yearsin Maintenance & Inbound Logistics

ERP Systems: An Overview

Plant Maintenance: An Overview

Organizational Structure

Master Data in SAP PM

Maintenance Processing: Objects

Maintenance Processing: Scenarios

Advanced scenarios, Interfaces & Reports

Organization

Government & Authorities

Customers

Environment

Vendors

Organizational ERP

System

Purchasin

g

Sales &

Distributio

n

Projects

Government & Authorities

Productio

n

Planning

Vendors

Customers

External Environment

Finance &

Controllin

g

HR &

Payroll

Maintena

nce

Maintenance is a Support Function within an Organization and Maintenance

costs generally constitute a part of Production overhead costs except when

Maintenance is carried out on Customer Assets to earn revenue.

Primary Objective of Maintenance is to maintain a high level of Availability,

preventing degeneration and maintaining optimal utilization life of an

Organization’s Physical Assets.

Physical Assets primarily comprise:

Fixed assets such as Plant & Machinery, Buildings & Properties, Vehicles and

so on. Usually such assets have a Long useful life (usually > 1 year) over which

they are depreciated

Operating Assets which may not be treated as Assets in Financial Module nor

depreciated, but having a long term utilization

High valued current assets such as High valued spares/operating

supplies/machine parts which are subject to Refurbishments with their condition

based values maintained accurately

Key Performance objectives in Maintenance include

Maintaining a high level of OEE (Overall Equipment Effectiveness)

Maintaining and Optimal balance between Cost of Breakdown vs. Cost of

Prevention

Utilizing concepts such as TPM, RCM etc. to contribute in Lowering Operating

costs and minimize adverse effects on Equipment ,Operating resources and

Environment

Company Code

Maintenance Planning

Plant

Maintenance Plant

Maintenance Plant

Maintenance Planning

Plant

Maintenance Plant

Centralized

Planning

De-centralized

Planning

SAP PM:

Master Data

Technical Objects

Planning Objects

Others

Work Centres

Capacity information includes:

Unit of capacity

Start/End times

Utilizations

Shift schedules etc.

Capacity

PM Work Centre Category “0005”

Comprises: Basic data, Default values, Capacity view, Scheduling view, HR Assignments, Costing view

Work Centre

Work Centre

Hierarchy

Work Centre Hierarchy is a

Grouping of Work centres

comprising Maintenance Task

Force

Capacity Functionalities

Capacity Leveling

Capacity Planning

Load Monitoring

Functional Locations

Equipment

Sub Equipment

Equipment Bill of Material

Component material parts

Serial Number

Material No

Structured into Hierarchical

Levels using Structure

Indicators

Plan

Task List

Maintenance item

Bottom up

planning

Top Down

planning

Plans

• Single cycle Plans

• Strategy Based Plans

• Counter Based Plans (Single/Multi Counter)

Task Lists

• General Task Lists

• Functional Location Task Lists

• Equipment Task Lists

Items

• Standard items

• Strategy based items

Permits

Class/

Characteristics

Measuring Points/Counters

Other Master

Data

Maintenance Notifications vs. Maintenance

Orders

Maintenance Notifications are Reporting objects to record:

Maintenance requirement

Cause, Object Impacted, Tasks due & Activities Performed

Types: Maintenance Request, Malfunction (Breakdown) Report, Activity Report, Service Notifications

Maintenance Notifications generally do not record Costs

Maintenance Orders are a complete record of:

Operations performed

Components used (Stock/Non stock)

Services hired

Time and costs posted

Settlements executed

Types: Breakdown Orders, Planned Orders, Predictive Orders, Calibrations Orders, Refurbishment Orders, Capital Work Orders

Order (Type

PM01) created

Convert to PM

Order?

Assigned permits if

any are issued by

relevant personnel

Is stock part

available?

Purchase

requisition created

(MM side)

Approved purchase

requisitions converted to

Purchase order

Yes

YesNo

Notification user

status changed to

ALWD and

notification

released

PM Oredr

Planning done

(Operation,

Components,

Service, Permits)

Order user status

changed to PLND

and order released

No

Stock part

Y

Issue stock part to Reservation No

assigned to PM Order

Master Data

Functional

LocationEquipment

Material

(Stock parts)

Permits (If

applicable)

Activity

Type

Equipment breaks

down

Shop papers

printed from

PM order

No

In SAP

Outside SAP

Service

Master record

Work center

(PM & PP)

Maintenance

Notification (Type

“M2”) created

Existing Notification

(Report IW29)?

No

Production personnel

follows up on work done

against existing

Notification

Yes

Yes

Is Stock part

planned?

No

Goods receipt to Storage

location

Is Non – stock

part planned?

Is Extenal

service

planned?

Purchase

requisition

created within

PM orderYes

Approved

purchase

requisitions

converted to

Purchase order

Goods receipt against PO

posts costs to associated

PM order

Purchase

requisition

created within

PM order

Approved

purchase

requisitions

converted to

Purchase order

Service acceptance

throughService entry

sheet against Service PO


PM order

Is Maintenance

work completed?

User status of

Maintenance order

changed to MTCO –

Completed by

Maintenance

Yes

Is further planning

required?

Yes

No

Production

personnel to

confirm Order

completion by

changing user

status to PRCO

Time confirmation

for Manhours with

suitable Activity

Type

Settlement rule defined in

order & Order Technically

completed with details of

Malfunction end date/time

Order settled to relevant

settlement receiver (Cost

Center)

Further work done is

recorded in

Notification&

Notification Tasks

Technically completed

No

SAP Notification mail to

designated Person

responsible in

Notification header


initiator of work

Scheduling overview

report generated by

maintenance

personnel on a

periodic basis

Assigned permits if

any are issued by

relevant personnel

Is stock part

available?

Purchase

requisition created

(MM side)

Approved purchase


Purchase order YesNo

Preventive

Maintenance order

(Type”PM02")

generated

Orders generated

for the periodare

planned further

(Operation,

Components,

Service, Permits)

Order user status

changed to PLND

and order released

No

Stock part

Y



Master Data

Functional

LocationEquipment

Material

(Stock parts)

Permits (If

applicable)Activity

Type

Yes

Shop papers

printed from

PM order

No

In SAP

Outside SAP

Maintenance

Task List

Work center

(PM & PP)

Is next call object –

Maintenance Order

due?

Yes

Is Stock part

planned?

No


location

Is Non – stock

part planned?

Is Extenal

service

planned?

Purchase

requisition

created within

PM orderYes

Approved

purchase

requisitions

converted to

Purchase order



PM order

Purchase

requisition

created within

PM order

Approved

purchase

requisitions

converted to

Purchase order

Service acceptance




PM order

Is Maintenance

work completed?

User status of

Maintenance order

changed to MTCO –

Completed by

Maintenance

Yes

Is further planning

required?

Yes

No

Production

personnel to

confirm Order

completion by

changing user

status to PRCO

Time confirmation

for Manhours with

suitable Activity

Type




Start/end date/time



Center)

Service

Master record

Maintenance

Plan

Counter (For

counter based

plans)

Maintenance Task

List created

Maintenance Plan

created (Single

cycle/Strategy

based/Counter

based)

Maintenance plan

scheduled

(Background job/

Manual)

Measurement

document posting

for Counter Based

plans

Planned Due

dates for order

creation are set in

system

Scheduling overview

report generated by

maintenance

personnel on a

periodic basis

Is stock part

available?

Purchase

requisition created

(MM side)

Approved purchase



Preventive

Maintenance order

(Type”PM02")

generated

Calibration Orders auto

generated and released

(Operation,

Components, Service,

Permits)

No

Stock part

Y



Master Data

Functional

LocationEquipment

Material

(Stock parts)

Permits (If

applicable)Activity

Type

Yes

Shop papers

printed from

PM order

No

In SAP

Outside SAP

Maintenance

Task List

Work center

(PM & PP)

Is next call object –

Maintenance Order

due?

Yes

Is Stock part

planned?

No


location

Is Non – stock

part planned?

Is Extenal

service

planned?

Purchase

requisition

created within

PM orderYes

Approved

purchase

requisitions

converted to

Purchase order



PM order

Purchase

requisition

created within

PM order

Approved

purchase

requisitions

converted to

Purchase order

Service acceptance




PM order

Is Maintenance

work completed?Yes

Is further planning

required?

Yes

No

Time confirmation

for Internal

Manhours with

suitable Activity

Type

Settlement rule set in

Calibration order

Service

Master record

Maintenance

Plan

Counter (For

counter based

plans)

Maintenance Task

List created

(Inspection point

300, MIC’s

entered)

Maintenance Plan

created (Single

cycle/Strategy

based/Counter

based)

Maintenance plan

scheduled

(Background job/

Manual)

Measurement

document posting

for Counter Based

plans

Planned Due

dates for order

creation are set in

system

Quality Inspection Lot

Generated

Result recording done

against Inspection Lot, Order



settlement receiver (Quality

Cost Center)

Order (Type

PM01) created

Convert to PM

Order?

Assigned permits if

any are issued by

relevant personnel

Is stock part

available?

Purchase

requisition created

(MM side)

Approved purchase


Purchase order

Yes

YesNo

Notification user

status changed to

ALWD and

notification

released

PM Oredr

Planning done

(Operation,

Components,

Service, Permits)

Order user status

changed to PLND

and order released

No

Stock part

Y



Master Data

Functional

LocationEquipment

Material

(Stock parts)

Permits (If

applicable)

Activity

Type

Scope for correction/

predictive maintenance

identified by Operator/

Maintenance person

Shop papers

printed from

PM order

No

In SAP

Outside SAP

Service

Master record

Work center

(PM & PP)

Maintenance

Notification (Type

“M1” Maintenance

request) created

Existing Notification

(Report IW29)?

No

Requestor checks on work

progress

Yes

Yes

Is Stock part

planned?

No


location

Is Non – stock

part planned?

Is Extenal

service

planned?

Purchase

requisition

created within

PM orderYes

Approved

purchase

requisitions

converted to

Purchase order



PM order

Purchase

requisition

created within

PM order

Approved

purchase

requisitions

converted to

Purchase order

Service acceptance




PM order

Is Maintenance

work completed?

User status of

Maintenance order

changed to MTCO –

Completed by

Maintenance

Yes

Is further planning

required?

Yes

No

Production

personnel to

confirm Order

completion by

changing user

status to PRCO

Time confirmation

for Manhours with

suitable Activity

Type




Start/ end date/time



Center)


initiator of work

Work detailed in

Notification and Tasks



designated Person

responsible in

Notification header

No

Capital work Order (Type

“PM06”) created – with

relevant Maintenance

Activity type assigned

Assigned permits if

any are issued by

relevant personnel

Is stock part

available?

Purchase

requisition created

(MM side)

Approved purchase



Order Planning

done (Operation,

Components,

Service, Permits),

Settlement rule

defined

Capital order

released

No

Stock part

Y



Master Data

Functional

Location

Asset Master –

AuC/FxA (As

relevant)

Material

(Stock parts)

Permits (If

applicable)

Activity

Type

Shop papers

printed from

PM order

No

In SAP

Outside SAP

Service

Master record

Work center

(PM & PP)

Yes

Is Stock part

planned?

No


location

Is Non – stock

part planned?

Is Extenal

service

planned?

Purchase

requisition

created within

PM orderYes

Approved

purchase

requisitions

converted to

Purchase order



PM order

Purchase

requisition

created within

PM order

Approved

purchase

requisitions

converted to

Purchase order

Yes

Service acceptance




PM order

Is Maintenance

work completed?Yes

Is further planning

required?

Yes

No

Time confirmation

for Manhours with

suitable Activity

Type

Periodic settlement

executed to relevant

receiver (AuC/FxA)

Asset under

construction created

by Business SAP

Finance Team

Maintenance Team

intimated on the AuC

Number

Capital work –

New asset build up

or Enhancement

New Asset buildup

Existing Equipment No (with

assigned Fixed asset) would

be identified

Asset Enhancement

Functional Location (for asset

build up created) as reference

Technical object

Equipment

(Associated to

FxA)

On completion of work Order

Technically completed with

necessary details

In case of Asset buildup work,

Finance finally settles AuC to

a FxA ( created)

Maintenance Team

intimated on the FxA

Number

Functional Location Structure

completed with assigned

Equipment tagged to FxA

number

Refurbishment order type

“PM04" created for Material

No, to convert from C3 -

Damaged to C2 -

Refurbished state

Purchase

requisition created

(MM side)

Approved purchase


Purchase order Yes

Order Planning done

(Operation – Internal or

External Services, Additional

Components if any),

Settlement rule defined

No

Stock part

Y



Master Data

Serial

NumberEquipment

Activity

Type Shop papers

printed from

PM order

No

In SAP

Outside SAP

Service

Master record

PM Work center

(For Internal

Refurbishment)

Additional

Stock parts

required/

planned?

No


location

Is Non – stock

part planned?

Is Extenal

Refurbishment

service

planned?

Purchase

requisition

created within

PM orderYes

Approved

purchase

requisitions

converted to

Purchase order



PM order

Purchase

requisition

created within

PM order

Approved

purchase

requisitions

converted to

Purchase order

Service acceptance




PM order

Is Maintenance

work completed?Yes

Is further planning

required?

Yes

No

Time confirmation

for Manhours with

suitable Activity

Type – In case of

internal manhour

consumed

Goods receipt of

Refurbished part (val. Type

“C2") to store

Need for Refurbishment

identified

Asset No

(Tagged to

Equipment ID)

On completion of work Order

Technically completed with

necessary details

Settlement executed to settle

order costs (As per business

requirement to FxA)

Ref. Material (with

valuation types

C1, C2, C3)

Batch Numbers for C1,

C2, C3 states of Ref

material

Damaged Material part

(valuation type C3) issued to

reservation no. in order

Order releasedAvailable in

stock?No

Yes







Integrations, Advanced scenarios, Interfaces & Reports

Equipment

Functional

Location

Fixed

Asset

BOM SparesPP Work

Center -

Machine

Plant Maintenance

Financial

Accounting

PM Work

Center

Order

Header

Operation

- Internal

Compone

nt

Operation

– Services

Shutdown

Notification

Maintenance

Plan

CostsMaterial Master

Service Master

Material Management

Controlling

Activity

Types

Sender Cost

Center

Receiver

Cost Center

QM Master

Equipments

Employe

e

Planned

Rates /hr

G/L

Account

PM - Customer Service Scenarios

PM - Work Clearance Management

PM – Fleet Management

PM – Mobile Asset Management

** PM – Project Oriented Maintenance

** PM – Linear Asset Management

** PM – Rotables Subcontracting

** PM – Inspection Rounds

** PM – Take over- Hand over of Equipments

** Functionalities available only in ECC 6.0 and in specific EHP versions

sap plant maintenance

Education

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maintenance costs

objects maintenance

sap pm cs

sap systems analyst

maintenance inbound

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