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SAP Plant Maintenance Overview for SAP ECC 6.0

SAP Plant Maintenance Overview for SAP ECC 6.0

  1. 1. SAP Plant Maintenance Overview Author: Alhadi A. Nibel SAP PM Associate Consultant
  2. 2. Plant Maintenance in the R/3 System Plant Maintenance:An overview Organizational Structure Master Data in SAP PM Maintenance Processing Business Process of Plant Maintenance SAPTransactions Course List
  3. 3. Plant Maintenance in the R/3 System
  4. 4. Plant Maintenance in the r/3 System • Plant Maintenance (PM) is a high-performance application component integrated in the logistics chain of the R/3 System that supports you when carrying out all maintenance tasks • The Plant Maintenance component supplements resource planning for the maintenance of your production systems, vehicles, buildings and so on, across all branches of industry.
  5. 5. PM application component has already been successfully implemented • Automotive industry • Chemical industry • Commerce/service industries • Energy suppliers • Electronics industry • Food industry • Mechanical engineering • Metal-working industry • Mining industry • Paper industry • Petrochemical industry • Pharmaceutical industry • Precision engineering • Primary industries • Public service industry • Publishing industry • Software and computing • Steel industry • Transportation industry
  6. 6. Plant Maintenance: An overview
  7. 7. What is SAP Plant Maintenance • Plant Maintenance is a function or an essential support system in an industrial process.This system helps and keep all the machinery and infrastructure into prime condition or ideal in terms of quality and operational. SAP Plant Maintenance comprises the following activities: • Inspection Determining the actual condition of a technical system • Preventive Maintenance Maintaining the ideal condition of a technical system • Repair Restoring the ideal condition of a technical system
  8. 8. Organizational Structure
  9. 9. Organizational Structure • Maintenance Planning Plant: Plant in which maintenance tasks are planned and prepared. Example: Maintenance planner group, maintenance work centers • Maintenance Plant: Plant in which the technical objects of a company are installed. Example: Building, production area
  10. 10. Master Data in SAP PM
  11. 11. Master Data in SAP PM SAP PM: Master Data Functional Location Equipment Bills of material Measuring Point/ Counters Class/ Characteristics Work Centres
  12. 12. Maintenance Work Center
  13. 13. Structured Clarification Functional Location Functional locations enable you to structure maintenance objects according to the following criteria: • Functional (for example, ”pump station,” ”power unit”) • Process-oriented (for example, ”polymerization,” ”condensation”) • Spatial (for example, ”hall,” ”location”)
  14. 14. • A piece of equipment is an individual physical object maintained as an autonomous unit. Pieces of equipment usually represent single objects such as pumps, motors, vehicles, for which maintenance tasks should be performed and recorded. • Equipment can be installed at functional locations.A piece of equipment can be linked with a material, if there is inventory management, in the sense of Materials Management, for the object. Equipment Hierarchy
  15. 15. Structure of a Bill of Material An individual bill of material can be defined for each maintenance object. The bill of material contains the following information: • Structure of the unit (using assemblies) • Spare parts for its maintenance (for example, stock items, external material, documents, and texts)
  16. 16. Maintenance Processing
  17. 17. Workflow-Supported Maintenance Processing for Unplanned MaintenanceTasks
  18. 18. • Direct creation of a maintenance order Order Notification Notification Notification Notification Notification Order Order Order • Creation of a maintenance notification with immediate order • Creation of a maintenance order based on a notification • Combination of maintenance notification to make a order Planning MaintenanceTasks
  19. 19. What is different between Notification andWork Order • 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) External Services Time, plan costs and actual costs posted Settlements executed • Types: Breakdown Orders, Corrective Orders, Predictive Orders, Refurbishment Orders, Preventive Orders
  20. 20. Business Process of Plant Maintenance
  21. 21. Breakdown Maintenance Corrective Maintenance Preventive Maintenance Refurbishment of Spare Parts Business Process of Plant Maintenance
  22. 22. Breakdown Maintenance Processing Notification Scheduling Execution Completion Technical object Description Date Malfunction Order release Printout Capacity leveling Availability check Planned/unplanned mat. withdrawal Time conf. Tech. completion Order settlement Technical confirmation Maintenance planner Technician/ Storeperson Maintenance supervisor Malfunction Reports Malfunction Order History Material usage, orders, notifications, PMIS, usage list
  23. 23. Corrective Maintenance Processing Notification Planning Scheduling Execution Completion Work to be performed Internal/external resources Material Tools Technical object Description Date Malfunction Order release Printout Capacity leveling Availability check Planned/unplanned mat. withdrawal Time conf. Tech. completion Order settlement Technical confirmation Maintenance planner Technician/ Storeperson Maintenance supervisor Internal External Service Material
  24. 24. Stock Material Process Flow (Reservation) Create Notification (IW21) Create Order refer from Notification (IW22) Order Planning, Assign operation, CTRL Key PM01, Input Stock Material (IW32) Order Release (IW32) Goods Issue Material (MIGO) Order Confirmation for ActualWork (IW41) OrderTechnical Completion (IW32) Order Settlement (KO88) Order Closure (CO99)
  25. 25. Procurement Non-Stock Material Process Flow Create Notification (IW21) Create Order refer from Notification (IW22) Order Planning, Assign operation, CTRL Key PM01, Non-Stock Material (IW32) Order Release (IW32) Release Purchase Requisition (ME54N) Create PO refer from Purchase Requisition (ME21N) Release PO (ME29N) Goods Receipt from PO (MIGO) Usage Decision/Quality Inspection (QA32) Order Confirmation for Actual Work (IW41) Order Technical Completion (IW32) Sys. Status - TECO Settlement a maintenance order (KO88) Order Closure (co99)
  26. 26. SAP Transactions
  27. 27. Func. Loc, equipment, and BOM Structure List
  28. 28. NotificationTransaction
  29. 29. Maintenance OrderTransaction
  30. 30. Report List of Order
  31. 31. Thank you • Contact information: Phone: (+62) 812-9790-0097 E-mail: alhadiakbar.official@gmail.com Krakatau Consulting – PT Krakatau InformationTechnology SAP Services & EBM Partner

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