sap pm level-1 material

7/29/2019 SAP PM Level-1 Material

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Satyam SAP Level -1Training for MPT

Plant Maintenance Module


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Plant Maintenance Overview

Unit:1Organization Levels

Unit:6Preventive Maintenance

Unit:2Technical Objects

Unit:3Breakdown Maintenance

Unit:4Corrective Maintenance

Unit:5Refurbishment

Unit:7Reporting


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Location Based Organizational Structure

MaintenancePlant

At which operational system

of company are installed

LocationIt Subdivide a maintenance

Plant according to Spatial criteria

Maintenance Work CentreIts an organizational unit where

Work can be carried out

e.g. site, buildingetc.

e.g.technicianmachine


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Planning based Organizational Structure

Maintenance Planning plant

Where maintenance requirementsare planned

Maintenance Planner groups

They defines planners within themaintenance planning plante.g. mech. planner, electrical planner etc.


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Types of Planning

Plant-Specific Planning(Decentralized Planning)

In mostorganizationalstructures, the maintenance requirement

is planned in the same plant where it occurs ,the maintenance ordersare executed by workshops from the same plant and inventory is

maintained at same plant

Cross-Plant Planning(Centralized Planning)

Multiple planning plants are assigned to a planning plant. In one

plant there is a need for maintenance, as a technical system thererequires maintenance.(= maintenance plant). All further functions

maintenance ,order execution, inventory management) are however,the responsibility of another plant maintenance plant)


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De-centralized Planning

Planning Types

Plant 1000 WarehouseInventory

Workshops

Maintenancerequirement

Planning ofMaintenancerequirements

Plant 1100

Workshops




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De-centralized Planning

Planning Types

Plant 1000 WarehouseInventory

Workshops

Plant 1200 Plant 1100

Workshops





Centralized Planning


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Work Center

A work center is an organizational unit within an operational system.

A work center can be one of the following:

MachineGroup of machinesPersonGroup of people

In Plant Maintenance, work centers are used as:

- Main work center in the master record for the equipment or functional location- Main work center in a maintenance item- Main work center in the task list header- Performing work center in the operations for a task list

- Main work center in the order header- Performing work center in the operations for an order

Work centers belong to the master data in PM and provide the capacityrequired to perform a task.


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Work center data

Work center data is used for the following business functions:

Basic Data - contains the description, work center category (for example,Plant Maintenance) and planned usage, person responsible.

Capacities - The available capacity is usually the standard available capacitywith the specifications - factory calendar, work start and end, number of

individual capacities (= number of people) and shift time per capita. Theavailable capacity can be restricted according to time, or organized in shiftsdifferent from the standard available capacity.

Scheduling - the operation dates are calculated based on the lead times(duration of operation), starting from the basic start and end dates.

Personnel Data - in addition to defining available capacity, people (=personnel numbers from Human Resources) or positions can be assigned inthe work center.


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Available capacity in work center

Available capacity is the work that can be provided by a unit of

capacity at a work center for each working day.

The available capacity refers to the capacity available within a certain period. Theavailable capacity is determined by:

1. Work start and finish times.2. Break lengths.3. Capacity utilization level of the capacity units.4. Number of individual capacity units that constitute the capacity.

The system stores the working time and the daily available capacity for eachwork center.

The available capacity can be defined for one work center or for all work centers.


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Technical Objects


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Function Location

Function Locations are hierarchically ordered

structures that represent a technical system,building, or part thereof

They are structured according to :

Spatial: E.g. Building 1, building 2

Technical : E.g. Press, Press frame, presshydraulics

Functional: E.g. Polymerization, condensation


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Criteria for Functional Location

To represent the structure of technical systems

according to functional criteria

Recording of Maintenance tasks

Storage and Evaluation of Technical data

Cost monitoring by area

Effects of usage condition on the installedequipment


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Function Location (Master Record)

General

Location

Organization

Structure

Equipments

Classification

Documents/Technical Drawings

Multilingual text

Address/Partner

Measuring Points/Counters

Permits


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To define the Functional Locations a template has to be used which is

called Structure Indicator.

The Structure Indicator helps in maintaining the hierarchies & control

usage of alphabets & numericals.

The newly created Functional Locations are automatically assigned to

its Superior Functional Location based on the Structure Indicator

Hierarchy.

The Functional Locations though assigned automatically, it can be

changed from the Structure tab in the Functional Location, by changing

the Superior FL.

Function Location Features


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Function Location Structure - Example

MPT

MPT-MOHP MPT-NMOHP

MPT-

MOHP-

UNLOAD

MPT-

MOHP-

CONV

MPT-

MOHP-

RECLAIM

MPT-

NMOHP-

SCHOOL

MPT-

NMOHP-

QUARTER


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Equipment

Equipment is an individual physical object that is to be maintained

as an autonomous unit and for which maintenancehistory should be constructed.

E.g. pumps, motors, vehicles etc.

Purpose of equipment :

To manage individual data for the object

Recording of maintenance tasks

Monitoring of maintenance tasks costs

Usage time of the object


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Machines

Fleet Objects

PRTs

Customer Equipment

Equipment Categories

Equipment categorisation is carried out using Equipment Category like


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Equipment (Master Record)

General

Location

Organization

Structure

Equipment Usage

Documents/ClassificationTechnical Drawings

Multilingual text

Address/Partner

Measuring Points/Counters

Permits

Internal Note


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Fleet Objects have specific data like

Identification Data

Dimension Data

Transport Relevant

data

Planning Data

Other Features

Engine Data

Fuel & Lub Data

Number Plate, Chassis Number

Height, Width, Length

Weight, Max Load, Loading Volume

Counter Reading data

Fuel card Number, key Number

Engine Type, Engine perf, RPM, CC

Fuel Type, Oil Type

Fleet Objects - Features


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Using FLs & Equipment

A Functional Location having some

equipment installed.

One such equipment is a DG Set

Level-1 Sub equipment

Engine

Level -2 Sub Equipment Engine Head

Level-3 Sub Equipment

Injectors


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Sub-Equipment


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Classification of Equipment

Classification is a cross-application function in the R/3 System that

is used by other application as well as Plant Maintenance.

One aim of classification is to assign features in detail to a technicalobject that the master record cannot handle in this quantity.

A classificationsystem describesobjects usingcharacteristics, andgrouping similar

objects into classes, toclassify them andmake them easier tofind.


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Characteristics


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Class Hierarchy

Classes can be used in hierarchy for better classification of the equipment.

Multiple levels of Class Hierarchy is possible.


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Object Networks

In a Industry different Networks could be there like, Eg: Water, Electricity,

Computer LAN, etc . These are to be defined in the system.


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Object Links

Reclaimer

Conveyor - 1

Conveyor - 2 Ship

By using the Object Links, the material flow can be easily known.

By taking a equipment for Maintenance, what other equipment are to be

stopped is also easily identifiable.

The Object links in reality can be Wires, Pipelines, etc.


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Bill of Material (BOM)

Bill of Material is a list of Materials for different uses in

different Modules

BOM Usage

Maintenance

Production

Engineering

Costing


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BOM Usages

BOM is a list of materials which are relevant for a usage.

The Engineering /Design usage BOM records all components of a

product according to engineering/design criteria and contains their

technical data.

The Production usage BOM records the items according to

production criteria and assembly status.

The costing usage BOM maps the product structure and provides

the basis for automatic determination of the direct material costs for

a product.

The Plant Maintenance usage BOM contains items only relevant tomaintenance only.

And like wise other usages of the BOM.


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BOM Use in Plant Maintenance

Structuring the Object

An Object should be structured as clearly as possible from a Maintenance

view point.

Spare Parts Planning

If a bill of Material is available for a maintenance object, this cab be easilyused to plan spares when planning a Maintenance Order.

Types of BOM in Plant Maintenance

BOMs for technical Objects ( FLs & Equipment).

BOMs for Materials.


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BOM Records

The BOM is stored in the Master Record of the respective Object.

For a Equipment BOM, it is stored in the Master Record of the Equipment.

For a Functional Location BOM, it is stored in the Master Record of the

Functional Location.

For a Material BOM, it is stored in the Master Record of the Material.


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Breakdown Maintenance

Business Scenario

For breakdown maintenance, the data required for the other businessprocesses needs to entered quickly and easily so that the

subsequent steps can be executed.


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Breakdown Maintenance order

Malfunction/Maintenance order

Execution

Completion

Starting point is the creation of maintenanceorder (possibly using data from the

maintenance notification) for damage or amalfunction. This is not a planned maintenanceorder, but it is immediately released forprocessing.

It comprises the removal of spare parts fromstock and the actual execution of the order.

The actual time required is confirmed.

Technical confirmation are also entered torecord the repair and condition of thetechnical system.


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Breakdown Maintenance Order

OrderCreate

andRelease

BreakdownReport/call/

message

Production Maintenance Planner

Technician

Malfunction

Correct/

Confirm

Maintenance Supervisor

OrderComplete

O d h h f


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Order with or without Notification

Order withoutNotification

Order withNotification

Breakdown order can be created

directly without any previousrequisition. It usually refers to atechnical object (Function Location orEquipment) and is configured at WorkCenter.

Breakdown Order can also becreated in combination with amaintenance notification, The orderthereby contains the same data asin above case and the notification

contains all the data relevant forthe documentation or history e.g.malfunction start or damage


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C ti M i t


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Corrective Maintenance

Notification

Planning

Scheduling

Execution

Completion

Malfunctions and other requirements are recordedE.g. Technical Object, Description, date,

Malfunction.

Order puts into processE.g. Order Release, Printout, Capacity LevelingAvailability Check

Order ExecutedE.g. Planned/Unplanned Material Withdrawn

Settlement of order done before or after this processE.g.Time Confirmation, Order Settlement, Technical

Completion, Technical Confirmation

Orders are created and planned on the basis of notificationE.g. Work to be performed, Material, Tools,

Internal/external resources

N tifi ti C t & N tifi ti T


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Notification Category & Notification Type

The List of Standard Notification Categories & Types is shown below.

M i t N tifi ti


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Maintenance Notification

It refers to a technical object and contains a description of themalfunction or requirement like modification work it can also contain

data for constructing a history e.g. damage, causes and so on.

Notification

Notification items

Activities

Tasks

Date time reported by

Description

Maintenance Object

Location data

Damage Location

Damage

Cause of Damage

Execution factors

Activity

Dates

Task description

Priority


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Priority

A priority can be assigned to each maintenance notification and order. Thispriority defines the required start and end dates for the notification or order,

relative to the creation date.

During maintenance processing, you can work with internal priority types for

notifications and orders. Since you can define an unlimited number of prioritiesfor each priority type, it is easier for the user to utilize the same priority typesfor notifications and orders; the same priority keys have the same meaning.

Startmaintenancenotification

Notificationsequence

Priority Type

PM

.

.

.

Priorities

1

2..

Relevant endand unit

Relevant startand unit

Catalog


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Catalog

Catalog

Code

Group

Damage

Mech-anical

For the coded entry of results and activities whilemaintaining notifications which is useful for analysis

Catalogs


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Catalogs

A cross-application catalog system is used for reporting maintenancenotifications. This catalog system has a hierarchical structure.

1. The first level of the catalog system is the catalog type. Each PM catalogtype represents a certain directory.

2. Each catalog type can be further subdivided using code groups.3. You can define individual codes within each group.

Catalog Type

DamageCause of damage

Activities

Object partsTasks

Code groups

VehiclesBuildingsMachines

.

.

Catalog Type

Torn drive beltBroken axle

Ripped oil pan

.

.

Order Creating & Planning


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Order Creating & Planning

Elements of Maintenance Order

Order Header Order Type, Dates, Plant, Reference Object,Priority, Description, etc.

Object list

Operation

Material list

Productionresources/tools

Settlement Rule

Costs

Equipment (assembly), function location,maintenance notification, etc.

Work Center, control key, description, standard

time, activity type, salary details etc.

Material, Quantity, Storage Location

Scheduling


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Scheduling

Scheduling in Preventive Maintenance orders

Scheduling is carried out for the operations based on different relationships

like FS,SS,FF,SF and also the logic backward or forward scheduling.

This will change the order basic start and end dates accordingly.

Scheduling in Corrective and Breakdown orders.

For breakdown orders there is no scheduling and only immediate execution

of the operations.

For corrective maintenance order there is no scheduling but earliest

execution of the operations in order.

Scheduling Parameters


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Scheduling Parameters

During Scheduling, the lead times for the operations are totaled and either added to

Basic Start Data (Forward Scheduling) or subtracted from the Basic Finish date

(Backward Scheduling). These dates may differ from basic dates

Scheduling


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In this order is subjected to various checks like materialavailability and capacity requirements and required shop

papers are printed.System can check in a single step whether all thematerials in the order are available, we useavailability check function for this.

System informs the result in an online message

Iftheres a lack of availability an error log can bedisplayed that contains detail data about theresult of the check.

Depends upon availability check if plannedmaterials are not available in sufficient quantity,system may or may not be able to release theorder depending upon customizing settings.

Material availability list can be displayed.

Scheduling

Permits


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Permits

Permits are used to adhere to health and safety regulations, and

control order processing. Permits can be used in two different ways.

As Technical permits assigned directly to the Technical Objects.

As process oriented permits with automatic assignment to the

order.

Technical Permits are assigned manually to the technical Object andnot classified (Eg: welding permit). If an order is created for the

technical object. The permits are copied to the order and can influence

the order release with a corresponding setting.

Process Oriented permits are determined automatically based on a

field in the order header (for Eg: Planned costs) and can likewise

influence the order release. Automatic determination is based on the

classified of the permit.

Order Release


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Reservation Effective

Papers can be printed

Confirmation Possible

Material can be withdrawn

Book good receipts

Complete Task

Order Release

Maintenenance Order - Printing Papers


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Job TicketIt gives the personexecuting the mainten-ance work a completeoverview of the order.

Control TicketShows to maintenanceengg. a completeoverview of the order.

Material Pick ListShows which material

has been planned forthe order. Object ListShows overview of theObject (Technicalobject, notifications)in the order

Time TicketTime required toexecute the operation

Confirmation slipUsed by workers as anentry sheet for theirwork times

Material withdrawlslip

Authorizes the personto take material fromwarehouse fororder

Maintenenance Order Printing Papers

Execution


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It Involves the withdrawl of spare parts from thewarehouse and actual execution of the order.

Pick List

Planned/unplannedmaterial withdrawl

OrderExecution as

peroperations

Execution

Completion


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After the work has been completed, the actual time required isconfirmed in the fifth and final step in Time Confirmation.

The Technical findings (damage, repairs performed, and so on..) and

the effects on the assets condition are recorded in the TechnicalConfirmation (TECO).

Technical confirmation indicates that the order is finished for PlantMaintenance.

Completion

Time Confirmation


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Individual Entry

Collective entry

Collective Entryusing

operation list

Overallcompletion

confirmation

Time Confirmation

Results of TECO


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Limited ability to change

order

Status Technically completed

Create Settlement rule

Deletion flag for purchaserequisition

Close open reservation

Close open capacities

Results of TECO


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Refurbishment


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Refurbishment

Production

Workshop / External Place

StoresNew

Intact

Refurbished To be Refurbished

Defect

To Scrap

Valuation Category & Types


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Valuation Category & Types

ConditionReference Origin

IInternal

EExternal

C1New Part

C2Refurbished

C3Defective

DDomestic

AAbroad

Valuation

categories

ValuationTypes

Price of Split Valuated Material


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Price of Split Valuated Material

Refurbishment - Cycle


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Equipment Removal+ Goods Receipt

Issue +Refurbishment

Goods Issue +

Equipment Installation

Return to Warehouse

FunctionalLocation

(SerializedEquipment)

WorkCentre

Warehouse

Warehouse

1 2

34

Refurbishment Cycle

Refurbishment


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Refurbishment

Process in SAP

A refurbishment Order is created in Order type PM 04

The Order is to be created on the material with respective plant &storage Location.

The Order should contain the number of pieces to be refurbished.

Plan the material & Manpower required for the refurbishment.

Withdraw the material from the stores.

Carryout the refurbishment of spares.

Carryout the Complete confirmation.

Post the Refurbished goods posting back to Stores.


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Preventive Maintenance


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To keep downtime and maintenance costs to a minimum, the technical

system in a company are inspected and maintained regularly.

Preventive maintenance is performed based on time, the condition or

the performance of the technical object.

Preventive

Maintenance

Performance

based

Time -based



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Process for Preventive Maintenance


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MFG. COMPETENCY(PP,PM&QM)

Task ListIt defines the steps to be carried

out on an object-dependent or

object independent basis

MaintenancePlan

It is created for the object and is

used to automatically generate

orders, notification or service entry

sheet with certain specification

Schedule

It is used to regularly call orders,

notification or service entry sheetand to recalculate planned dates

MaintenanceOrder

Order is automatically generated

from the maintenance plan and

included in the order list, where it

is processed like other orders

TechnicalCompletion

It flags the order and planned date

in the maintenance plan as complete,

date of technical completion is

used to calculate next planned date

Task List


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Task List

Maintenance task lists describe a series of individual maintenance

activities.

Task lists also specify which spare parts and tools are required foroperations and the time needed to perform the work.

If maintenance task lists is created, Maintenance orders can be createdand maintenance plans very easily, as operations and processes are

already entered in the maintenance task list.

If the same task is required again shortly afterwards, maintenance ordercan be created with reference to the maintenance task list.

Single Cycle maintenance Planning


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Scheduling data

Single Cycle maintenance Planning

A maintenance plan is used to generate a call objectautomatically for a particular date.

A call object can be a maintenance order, notification orservice entry sheet. Order and notification can also begenerated at the same time.

Structure of Maintenance Plan

Maintenance item

It contains the scheduling parameters for

the plan

It contains following data entries :

> Planning data> Reference object

> Task list

Single Cycle Plan Scheduling Parameters


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g y g

While creating single cycle plan, the cycle is assigned, that is, theperiod until eachplanned date(which is the due date of the measure.

Orders are generated based on planned date.

However , the call date (which is the order creation date) falls beforethe planned date, to allow a certain lead time (for material

procurement).

Cycle3 months



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g y g

Cycle startdefines the date from which the calculation of the planneddates should begin.

Scheduling periodspecifies the period for which planned dates should becalculated in advance. It can be used for time-based and performance

based preventive maintenance.

Planneddate

Scheduling Period(1 Year)

Strategy Plan


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gy

Business Scenario

Maintenance work and inspections are performed in different cycles.

Example: Service record for a fleet object (excerpt)

o Check fan belt: every 12 months

o Change fan belt: every 24 monthso Change oil: every 6 monthso Change oil filter: every 12 monthso Check air filter: every 12 monthso Change air filter: every 24 months



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Cycle start & Offsetdefines the date from which the calculation of theplanned dates should begin & which package should be in sequence.

Scheduling periodspecifies the period for which planned dates should becalculated in advance. It can be used for time-based and performance

based preventive maintenance.

Planneddate

Scheduling Period(1 Year)

H Q Y Q

Performance based strategy planning


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Preventive maintenance can be planned and performed using aperformance-based strategy and regularly entered counter

readings. The maintenance dates calculated are adjusted

automatically based on the counter readings entered.

Basic Scheduling Functions


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The scheduling of performance-based maintenance plans is based on the estimatedannual performance, which has been entered in the counter for the referenceobject.

The daily performanceis then calculated from the estimated annual performance.

A time period is then calculated from the daily performance andmaintenance cycle.By adding this time period to the start date of the maintenance plan,a newplanned dateis reached.

Example:

Estimated annual performance: 36,500 liters

Internal calculation of daily performance: 36.500 : 365 days = 100 liters per dayPlanned date for a cycle of 20,000 liters: 20.000 : 100 = 200 days,This means that, beginning from the cycle start, the first planned date is set after 200days.

CalculatedPlanned

date

Cycle :20,000 liters.

Multiple counter Plan


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For an airline company, changing the engine is dependent on two criteria: Number of flying hours

Number of take-offs/landingsThe engine should be replaced eitherafter 18,000 flying hours or after12,000 take-offs/landings.Amultiple counter plan, in which the two characteristics "Flying hours" and "Take-offs/landings" are linked, can be used here for planning and executing this task.

A multiple counter plan is a maintenance plan that can have cycles of differentdimensions. You can assign cycles freely to the multiple counter plan. A strategy cannotbe used here.

Based on the cycles entered, the counters from the reference object are proposed bycomparing the units.

BusinessScenario


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Usage List History


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g y

It displays phases, during which the equipment was installed at a functionallocation, assigned directly to a usage site (for example, a cost center), or stored ina warehouse.The usage list displays all the pieces of equipment that have been installed inchronological order.

Maintenance history


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Analyses in maintenance processing are based on completed notifications or orders and historical orders.Completed notifications and ordersA notification is transferred to the notification history when completed, whereas an order istransferred to the section for completed orders.Evaluations can be performed in the corresponding list editing function, where the status "Completed"must be set each time.Historical ordersHistorical orders are generated when completed orders are archived and they form the basis for long-termanalyses. They are transferred to the order history. Evaluations can be performed in the list editingfunction for the orders, where the status "Historical" must be set.

Maintenance Cost Analysis


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Standard Maintenance Cost Analysis are present in SAP.

Analysis based on

Functional Locations

Equipment

Work Center

Object Type

Order Types

Maintenance Activity Types

Plant Sections

ABC Analysis

MTBF, MTTR etc.