Plant maint p pt-wisdom

breaking through barriers to progress

Plant Maintenance in SAP
A functional perspective

By – Gopinath

an award winning '2004 Future 50 Company'
18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.0200

SAP R/3 - Overview

Overview: R/3 Overview and Integration
TeamSAP Academy
R/3 Overview &
Integration

Getting Started R/3 Applications
SD FI
Sales &
Sales Financial
Distribution Accounting
CO
MM Controlling
Materials
Materials
PP Mgmt AM
Production Asset Mgmt

R/3
Mgmt
Planning
Planning

QM
Quality
Client / Server Project
PS
Mgmt
PM ABAP WF
System

Plant Main-
Plant
Workflow
tenance
HR IS
Human Industry
Resources Solutions

Support & Services

System-Wide Concepts

R

© SAP AG

2

Plant Maintenance - Overview

SAP R/3 Modules

SD FI
Logistics Sales &
Financial Accounting
Accounting
Distrib.
Distrib.
MM CO
Material
Manag. Controlling
Manag.
PP TR
Production

R/3
Treasury
Planning

QM
Quality
Client / Server PS
Project
Manag.
Manag.
PM ABAP WF
System

Plant Workflow
Maint.
Maint.
HR IS
Human Industry
Resources. Solutions

Human Resources Cross Application
Functions R

© SAP AG

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SD FI
MM CO

What Is Integration? PP

QA R/3
AM

PS
PM WF
HR IS

Common organizational structures throughout
the system
Seamless processing of common data between
applications
Comprehensive support and reference tools
Common reporting features and functionality
Object and application linking and overall system
communication

R

© SAP AG

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Organization of Plant Maintenance:
Business Scenario

Plant Maintenance is an integral part
of the company and has numerous
links to other enterprise areas.
Depending on the company structure,
maintenance planning is either plant-
based (decentralized) or cross-plant
(centralized).

© SAP AG 1999

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Structure of Plant Maintenance

EQM Technical Data
Functional locations
Equipment
Assemblies
Bills of material
Networks of technical objects

PRM Preventive Maintenance
Task lists
Maintenance plans

WOC Maintenance Processing
Maintenance notifications
Maintenance orders

PMIS Plant Maintenance Information System

CRP Work Centers and Capacity
Maintenance work centers

© SAP AG 1999

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Concept of Plant Maintenance

Master data

Characteristics Cost records Bills of material
Classes Cost center
Task lists
Maintenance
Equipment / work centers
functional locations Maintenance
strategies

Planning
Maintenance Maintenance
notification plans

Order processing Maintenance
order
Material Purchase
reservation Capacity requisition
load
Purchase orders / Goods receipt /
Material
Time release order invoice receipt
issues
confirmation
© SAP AG 1999

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Organizational Structures in Plant Maintenance

General Organizational Units in Logistics

Client
Company code

Plant

Location-Based Organizational Units

Maintenance plant
For example, site,
Location building, coordinate

Plant section For example, production
area, plant engineer

Planning-Based Organizational Units
Maintenance
planning plant Maintenance For example, foreman,
planner groups work scheduling
Maintenance
For example, mechanics
work centers

© SAP AG 1999

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Cross-Plant Maintenance

Plant 1200 Plant 1300

Maintenance Maintenance
requirement requirement

Workshops

Warehouse
Plant 1000

Planning of
Maintenance
maintenance
requirement
requirements

Workshops
Material

© SAP AG 1999

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Maintenance Work Centers

Maintenance work centers

For example:
Welding
Metalworking
Mechanics

© SAP AG 1999

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Work Center: Contents

Basic data
General data

Capacity data
Capacity categories Capacity / pool capacity
Scheduling Available capacity profile

Links Activity types
Activity types
Activity types
Cost center
Work center
Person Staffing assignment
Staffing assignment
Qualification
Staffing assignment Time

© SAP AG 1999

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Work Center: Main Functions

Work Center
Work Center

11
10
Default values
Default values Scheduling
Scheduling
for task lists
for task lists Costing
Costing data and
data and
and orders
and orders data
data available capacity
available capacity

Lead time
Lead time
Task list // order
Task list order Costing
Costing scheduling
scheduling
Capacity planning
Capacity planning

2,724.00
2,724.00
1,200.00
1,200.00
124.00
124.00

4,048.00
4,048.00

© SAP AG 1999

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Functional Location

Functional location = multi-level, hierarchical structure,
organized according to ...

Spatial

Technical

Functional

Criteria
© SAP AG 1999

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Criteria for Functional Locations

When is a functional location created?

Execution of maintenance tasks
Recording of maintenance tasks
Data collection over long periods
of time
Cost monitoring by area
What effect do the usage
conditions have on the
likelihood of damage to the
installed aggregates?

© SAP AG 1999

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Automatic Assignment Upon Creation

C1
Clarification
Existing plant
functional C1-M C1-B
Mechanical Biological
locations cleaning cleaning

C1-M01 C1-M02 C1-B01 C1-B02
Sand Oil/fat Pump Filtering
trap trap plant station

New
C1-M01-2
C1-M01-2 C1-M02-2 C1-B01-1 C1-B02-2
functional Ventilator Ventilator Pump 1 Filter cell
Ventilator
locations

© SAP AG 1999

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Example of Functional Location Structure

C1
Clarification
plant
C1-M C1-B
Mechanical Biological
cleaning cleaning

C1-M01 C1-M02 C1-B01 C1-B02
Sand Oil/fat Pump Filtering
trap trap plant station

C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3 C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2
Sand Fat Filter
Reservoir Ventilator dredger Reservoir Ventilator dredger Pump 1 Pump 2 Ventilator cell

C1-B02-1A C1-B02-1B C1-B02-2A C1-B02-2B C1-B02-2C
Filtrate
Valve 1 Valve 2 Inlet level Outlet

C1-B02-2A/1 C1-B02-2A/2 C1-B02-2C/1 C1-B02-2C/2
Valve 1 Valve 2 Valve 1 Valve 2

© SAP AG 1999

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Criteria for Equipment Master Record

When is a piece of equipment created?

Management of individual data

Recording of maintenance tasks

Object-based recording of costs

Evaluation of technical data

Recording of usage times

© SAP AG 1999

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Equipment Master Record

Location A

Equipment master record
Equipment master record Equipment usage
Location B

List

Classification X
X
X
X
X
X

X

General
General Documents /
technical drawings
Location
Location
Multilingual texts

Organization
Organization Address / partner

Measuring points / 0471
Structure counters 0123

Permits

Internal note

© SAP AG 1999

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Bills of Material in Company

Production
bill of material Engineering/design
bill of material

Maintenance
bill of material
Costing
© SAP AG 1999
bill of material

19


Breakdown Maintenance: Business Scenario

For breakdown maintenance, the
data required for the other business
processes needs to entered quickly
and easily so that the subsequent
steps can be executed.

© SAP AG 1999

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Business Process: Breakdown Maintenance

1 Notification • Technical object • Date
• Description • Malfunction

2 1 Planning • Work to be performed • Material
• Internal/external resources • Tools

3 Scheduling • Order release • Capacity leveling
• Printout • Availability check

4 2 Execution
Execution
• Planned/unplanned material withdrawal
• External procurement

5 3 Completion
• Time confirmation • Order settlement
• Technical completion • Technical confirmation

History
Material usage, orders, notifications, PMIS, usage list

© SAP AG 1999

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Maintenance Order: Putting in Process

Status
'RELEASED'

Order papers
Put in process

© SAP AG 1999

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Time Confirmations

Initial screen Individual entry
Collective entry
Collective entry using operation list
Overall completion confirmation

Scope Partial confirmation
Final confirmation

Reversal option

© SAP AG 1999

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Maintenance Order: Technical Completion

Order 901760
Limited ability to change order

Status 'Technically completed'

Define location and account assignment data

Create settlement rule

Set deletion flag for purchase requisitions

Close open reservations

Close open capacities

© SAP AG 1999

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Cycle for Corrective Maintenance

1 • Technical object • Date
Notification • Description • Malfunction

2 • Work to be performed • Material
Planning • Internal/external resources • Tools


4 Execution • Planned/unplanned material withdrawal

5 Completion • Time confirmation • Order settlement

History

© SAP AG 1999

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Definition of Maintenance Notification

Describes the condition of a maintenance object,
particularly a malfunction

Malfunction report

Describes a maintenance activity already performed
(purely technical documentation)

Activity report

Requests a maintenance service/task

Maintenance request

© SAP AG 1999

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Maintenance Notification: Structure

Date / time / reported by
Notification Description
Object: Functional location
Equipment
Assembly
Material serial number
Location data
Breakdown / availability

Damage location
Notification
Text Damage
items
Cause of damage

Activity
Activities
Execution factors

Dates
Tasks
Task description

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Maintenance Notification: Object Information

Orders

Maintenance dates Notifications

i
Processing days
Documents

Object information

Links Structure list

Breakdowns

© SAP AG 1999

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Select Maintenance Notifications

Why ?
Find particular maintenance notification
Process several maintenance
notifications simultaneously
Restrict planning worklist
Scope
Notification
Notification items
Tasks
Customizing

Selection conditions
Field selection

Functions
Different sorting
Select / delete complete list
Different list fields, internal display variant
Display breakdowns graphically
Excel processing
© SAP AG 1999

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Print Maintenance Notifications

Maintenance
Fax transfer
notification

Notification
overview Activity
report
Breakdown
report

© SAP AG 1999

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Creation of Maintenance Orders

Direct creation
Maintenance order / notification
of order

Creation of order Maintenance Maintenance
based on notification notification order

Maintenance
notification
Combination of Maintenance Maintenance
maintenance notifications notification order
for maintenance order Maintenance
notification

Entry of order with Maintenance Maintenance
subsequent activity report order notification

Automatic generation of Maintenance Maintenance
maintenance order item order
from maintenance item

© SAP AG 1999

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Characteristics of Maintenance Orders

Flexibility of order processing

Object reference
Single object
Object list

Period of validity

Single order
Standing order

Execution
Internal processing
External processing

© SAP AG 1999

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Stock Material - Process Flow

Component
assignment

Material
reservation

Order
Availability
release
check May

Printing
Automatic
availability
check May
Goods
issue
© SAP AG 1999

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Resource Planning: Availability Check

Plant Material withdrawal
stock for cost center

Stock transfer
to other plant
Inward stock
movement
from purchase
order
Inward stock movement
from internal production
Stock
profile
Maximum
ATP quantity
Safety
stock

Today Requirement date

© SAP AG 1999

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Maintenance Order: Printing

Maintenance
Fax transfer
order

Job ticket
Material
withdrawal
Operation
slip
control ticket

Confirmation
Pick list
slip
Time ticket
Object list

© SAP AG 1999

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Order Completion Confirmation: Times / Activities

Times
Individual entry
Collective entry
Time sheet (CATS)

Activities
Activity reports
Confirmation texts

Object changes

Measurement readings

© SAP AG 1999

38


•Questions ??

•Contact Details :
mail id : gthangavelu@darylflood.com
Cell : 469-879-4674
Residence : 972-444-8510

39

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