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SAP PM Master Data Training Guide

Step by step Instructions for Plant Maintenance Master Data Management in SAP

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SAP PM Master Data Training Guide

  1. 1. SAP PLANT MAINTENANCE MASTER DATA ASHUTOSH SHARMA SAP PM Consultant IBM Global Business Consultancy Services
  2. 2. Overview Master data Data maintained once and can be used number of transaction is known as master data. Plant Maintenance master data can be classified as below 1) FUNCTIONAL LOCATION 2) EQUIPMENT 3) BILL OF MATERIAL MATERIAL BOM, FUNCTIONAL LOCATION BOM EQUIPMENT BOM, 4) SERIAL NUMBER 5) MEASURING POINT/COUNTERS 6) MEASURING DOCUMENTS 7) WORK CENTRE 8) TASKLIST GENERAL MAINTENANCE TASK LIST FLOC TASK LIST EQUIPMENT TASK LIST 9) PERMIT 10) WARRANTY
  3. 3. 1) FUNCTIONAL LOCATION Functional locations are hierarchically ordered structures that represent a technical system, building, or part thereof. Functional location is created to structure a technical system or building into units that are relevant for Plant Maintenance. Functional location can be structured according to Spatial - Space oriented criteria e.g. Building Functional - Process oriented criteria eg. Polymerization Technical - technology oriented criteria e.g. Press hydraulics Functional Location Master • Functional Location is created to represent structure of technical system of the company according to functional criteria. • Functional Location is created when maintenance tasks have to be performed for individual areas in the structure of the technical system and this work must or should be recorded. • Functional Location is created when technical data for certain parts of the technical system has to be stored and evaluated over a long period of time. • Functional Location is created the costs of maintenance tasks have to be monitored for certain parts of the technical system. • Functional Location is created when one want to analyze what effects the usage conditions have on the the likelihood of damage to the installed equipment. FUNCTIONL LOCATION MASTER RECORD The master record for functional location uses following views General: Class, Object Type, Reference Data Location: Location data, address Organization: Account assignment, responsibilities Structure: Structure indicator, higher-level functional location, equipment Additional data or links in the master record for the functional location can also be activated as tab pages or called up using pushbuttons
  4. 4. Nomenclature of functional depends on the structure indicator define in customizing The identification for functional locations is created using the structure indicator. The structure indicator consists of two input fields: Edit mask Hierarchy levels 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. The hierarchy levels are used to define which level ends at which character and how many hierarchy levels the structure may contain. A functional location can be identified using a maximum of 40 characters (= maximum length of the edit mask). STRUCTURE INDICATOR Edit mask Hierarchy levels A = Alpha N = Numeric X = Alphanumeric System Area Sub-area Function Sub-function Item Location number A1 A1-B A1-B02 A1-B02- 9 A1-B02- 9-C A1-B02- 9-C- 1 1 2 3 4 5 6 AN-ANN-N-X-X
  5. 5. Create Functional Location (IL01) Change Functional Location (IL02) Display Functional Location (IL03)
  6. 6. The structure of the functional location is based on the structure indicator. If you create a new functional location (for example, C1-M01-2), the system checks whether a hierarchy with this structure indicator already exists and whether the new identification is suitable for the existing hierarchy. If this is the case, when the new functional location is created, it is included in the existing structure automatically. CUSTOMIZING ELEMENTS Structure indicator Functional Location Category AUTOMATIC ASSIGNMENT UPON CREATION C1-B Biological cleaning C1C1 ClarificationClarification plantplant C1-M Mechanical cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station Existing functional locations New functional locations C1-M01-2 Ventilator C1-M01-2 Ventilator C1-M02-2 Ventilator C1-B01-1 Pump 1 C1-B02-2 Filter cell
  7. 7. 2) EQUIPMENT A piece of equipment is an individual physical object that is to be maintained as an autonomous unit. Equipment can be of below mentioned types Test equipment Customer equipment Production resource Tool Building, Property Vehicles Systems, Systems parts Pieces of equipment usually represent single objects (for example, pumps, motors, vehicles), for which maintenance tasks should be recorded. Equipments can be installed or dismantled at functional locations EQUIMENT MASTER Equipment is created when individual data for the object has needs to be managed. Breakdown, planned or preventive maintenance tasks are required for an object and must be managed. Technical data for the object needs to be collected and evaluated over long periods of time. The costs of maintenance tasks for this object are to be monitored. You need to record the usage time of this object at functional locations. EQUIPMENT MASTER RECORD The master record for EQUIPMENT uses following views General: Class, Object Type, Reference Data, manufacturer data Location: Location data, address Organization: Account assignment, responsibilities Structure: Structure indicator, higher-level functional location, equipment Additional data or links in the master record for the functional location can also be activated as tab pages or called up using pushbuttons
  8. 8. Create Equipment (IE01) Change Equipment (IE02) Display Equipment (IE03)
  9. 9. Equipment installation at Functional Location Two prerequisites must be fulfilled for a piece of equipment to be installed at a functional location The equipment category must permit an installation (Customizing). The option "Equipment installation allowed" must be activated in the master record for the functional location. You can restrict this option by using the "Individual installation" option. CUSTOMIZING EQUIPMENT CATEGORIES CATEGORY NUMBER RANGE BUSINESS VIEWS PROFILE USAGE HISTORY OBJECT TYPES INSTALLATION AT FUNCTIONAL LOCATION FIELD SELECTION FOR EQUIPMENT MASTER RECORD INTEGRATION WITH ASSET ACCOUNTING
  10. 10. 3) BILLS OF MATERIAL Bills of material are used for different purposes. The usage depends on the enterprise area, for example: 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 production bill of material includes the items (from a production viewpoint) and assembly conditions. For the assembly, for example, only items relevant to production with process-oriented data are required. 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 BILLS OF MATERIALS IN A COMPANY Engineering/design bill of material Costing bill of material Production bill of material Maintenance bill of material
  11. 11. The maintenance bill of material differs from other BOM’s in that it only contains items relevant to Plant Maintenance. The maintenance bill of material has three important functions: 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. There are three categories of maintenance bill of material: Material BOM Equipment BOM Functional location BOM BILLS OF MATERIAL IN PLANT MAINTENANCE Maintenance bill of material Structuring of object Spare parts planning in task list Technical object Spare parts planning in order
  15. 15. CUSTOMIZING BOM Define BOM usage Define item categories
  16. 16. 4) SERIAL NUMBER Serialization enables inventory management of a piece of equipment. Assigning serial number to a piece of equipment enables the piece of equipment to be managed from an inventory management perspective You can manage the relationship between the material and the equipment as follows: You can synchronize the equipment number and the serial number with each other. You can synchronize the material coupled with the equipment with the material in the Construction Type field of the equipment (Structure tab page). The standard display of the Serialization Data view in the equipment master record can be preset in the Customizing settings for the equipment category.
  18. 18. CUSTOMIZATION Serial Number Profiles Serialization operations and movement types
  19. 19. 5) MEASURING POINT/COUNTERS Measuring points are physical and/or logical locations at which a particular condition is described - for example, the temperature of coolant in a nuclear power station after an outflow from the pressure vessels, or the number of rotations per minute of the rotary blades of a wind-driven power station. Measuring points are located at technical objects. Counters are resources that enable you to represent the wear and tear of an object or the consumption or reduction in its useful life - for example, the mileage indicator of a motor vehicle or the electricity consumption meter of an electrically-powered system. Counters are located at technical objects. Measurement or counter readings can be entered for each object to be maintained.
  20. 20. CREATE MEASURING POINT (IK01) CHANGE MEASURING POINT (IK02) DISPLAY MEASURING POINT (IK03) For creating counter please check the MeasPoint is counter check box
  21. 21. CUSTOMIZATION Measuring Point Categories
  22. 22. 6) MEASUREMENT DOCUMENTS A measurement document is the overall term used to describe the data entered in the system after measurement at a measuring point or after a meter reading. A measurement document consists of the following data sections: Measuring point data: This refers, for example, to the measuring point number, measurement position, description, characteristic, and unit. Measurement result data: This refers to the precise second when the measurement or reading (time stamp) takes place, the measurement or counter reading respectively, as well as a qualitative assessment of the measurement result if necessary. CREATE MEASUREMENT DOCUMENT (IK11)
  24. 24. A work center is an organizational unit within an operational system. A work center can be one of the following: Machine Group of machines Person Group 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 capacity required to perform a task.
  25. 25. The basic data contains general data such as work center category, description, responsibility, and usage. Work center links provide the connection between work centers and other objects within the SAP System. You can link a work center to the following objects: Cost center Qualifications Staffing positions People The links are valid for certain periods of time. WORK CENTRE: CONTENTS Basic data General data Capacity data Capacity categories Scheduling Capacity / pool capacity Available capacity profile T i m e LinksLinks Activity types Activity types Activity types Work center Person Qualification Staffing assignment Cost center
  26. 26. Costing: Costing can be used to determine the costs of an internal activity by a product unit. The aim of costing is to attribute the costs incurred to the individual cost objects. It uses the work center to link the operation to cost accounting by maintaining cost centers and activity types. If the work center is used in an operation, standard values can be entered for the activity types specified in the work center. Scheduling: You can use scheduling to determine the dates when operations should be performed. For this, the time required for the operations must be calculated and compared with the time available in the work center. The standard values and quantities in the operations are used as the basis for this calculation. During scheduling, the start and end dates for the operations are calculated from this data using formulas, which have been entered for scheduling in the work centers. Capacity planning: In capacity planning, the capacity requirements for the operations in the orders are determined and compared with the available capacity defined in the work center. During capacity planning, you can use work center hierarchies to aggregate (at higher-level work centers) the available capacity and capacity requirements of lower-level work centers.
  28. 28. 8) TASKLIST Maintenance task lists describe a series of individual maintenance activities. You can use them to standardize recurring activities, plan them more effectively, and save time when creating maintenance orders and maintenance plans. In the Plant Maintenance system, maintenance task lists can be used for routine and preventive maintenance work. Task lists also specify which spare parts and tools are required for operations and the time needed to perform the work. If you have created maintenance task lists, you can create maintenance orders and maintenance plans very easily, since you refer to the operations and processes already entered in the maintenance task list. This means that if you create a maintenance order for a task, for which all the individual operations have already been described in a maintenance task list, you only need to specify this task list and the required times in the maintenance order. You do not need not to enter the individual operations because they are copied from the maintenance task list. If the same task is required again shortly afterwards, you can again create the maintenance order with reference to the maintenance task list.
  29. 29. The following assignments are made in the task list header: Planner group, maintenance strategy, and a series of other parameters The following assignments are possible for operations: Time, components, work center, and a series of other parameters Three types of task lists are available IN Plant Maintenance. They are distinguished by an indicator: Equipment task list (E) Functional location task list (T) General maintenance task list (A) MAINTENANCE TASK LIST Task list header Operation 10 Operation 20 Operation 30 Planner group Maintenance Strategy 3 months3 months 6 months6 months 12 months12 months Work center Production Resources/tools Components
  30. 30. Equipment task lists are always object-based and created for a specific, individual piece of equipment (example: steps for calibrating measuring device M-105). Task lists for functional locations are also object-related and created for a specific functional location (example: steps for inspecting hydraulic press HP-200). General maintenance task lists are general task lists without object reference (example: general steps for pump maintenance). All three task list types can be used for routine and preventive maintenance. Create Functional Location Task List (IA11)
  31. 31. Change Functional Location Task List (IA12) Display Functional Location Task List (IA13)
  32. 32. Create Equipment Task List (IA01) Change Equipment Task List (IA02)
  33. 33. Display Equipment Task List (IA03)
  34. 34. Create General Maintenance Task List (IA05) Change General Maintenance Task List (IA06)
  35. 35. Display General Maintenance Task List (IA07)
  36. 36. CUSTOMIZATION Profile User field Control Key Number Range Presetting for free material assignment 9) PERMIT
  37. 37. Permits are used to adhere to health and safety regulations, and control order processing. It can be used to ensure that special approval has been obtained before orders are executed. Permits can be used in plant maintenance in two ways: As technical permits assigned to technical objects As process-oriented permits with automatic assignment to the order Technical permits are assigned manually to the technical object and not classified (for example, 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 example, planned costs) and can likewise influence the order release. Automatic determination is based on the classification of the permit. Create Permit (IPMD)
  38. 38. 10) WARRANTY
  39. 39. A warranty is a binding commitment to the customer to provide services, partly or fully without cost, for a specified period of time, or for the specific life of an individual device. Warranties define the scope of the services that a company performs at a technical object in the event of damage or problems. Warranties can be assigned to piece of equipments, functional Locations or serial numbers. Before creating a warranty master record, warranty type should be defined Warranty type indicates how a warranty should be used. The warranty type is assigned to an internal warranty category that specifies whether the company for which the system user works is a warrantee or guarantor. STRUCTURE OF MASTER WARRANTY The warranty categories are strictly defined within the system and cannot be modified. There are two types of warranty category: Warantee: The warranty comes from an outside party, for example, buy a new piece of equipment and receive a warranty from the manufacturer that covers a certain period or usage (manufacturer warranty). Guarantor: The warranty is internal and goes to the customer, for example, sell or lease a piece of equipment and concede a warranty to your customer. MASTER WARRANTY WARRANTY HEADER WARRANTY ITEMS WARRANTY COUNTER Warranty Type, Description, Classification Service activities Counters, Limits
  40. 40. The following warranty categories are available in the standard SAP System: Warranty category I This warranty category is available if you are the warrantee. Warranty category O This warranty category is available if you are the guarantor. Create Master Warranty (BGM1) Change Master Warranty (BGM2) Display Master Warranty (BGM3)
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