Dawn Foods - S4/HANA Implementation Project (Level I – Training) Plant Maintenance (PM) 03-April-2021 Copyright © 2021 AbacusConsulting. All rights reserved. AGENDA ERP Systems • What is an Enterprise Resource Planning? SAP PM - Organization Structure Technical Object Maintenance Business Processes • Corrective • Breakdown • Preventive • Calibration Enterprise Resource Planning SAP stands for Systems Applications and Products in Data Processing. SAP ERP is an enterprise resource planning software developed by the German company SAP SE. SAP ERP incorporates the key business functions of an organization. SAP PM – Organizational Structure General Organizational Units in Logistics Client Company code Plant Location-Based Organizational Units Maintenance Plants Location Plant Section Planning-Based Organizational Units Maintenance Planning Plants Planner Groups SAP PM – Organizational Structure Company Code • A Company Code represents an independent financial unit. • A Company Code has its own Balance Sheet and Profit & Loss Statement Company Code 1000 Description Dawn Foods SAP PM – Organizational Structure Maintenance Plant • The Maintenance plant is the plant where the technical objects (Functional Location, Equipment) are physically present in the plant • Maintenance Activities are carried out in this area. Company Code 1000 Maintenance Plant 1000 Description Dawn Foods-Lahore SAP PM – Organizational Structure Maintenance Planning Plant • The Planning plant is the plant in which the maintenance for the object (Functional Location, Equipment) are planned and prepared. • Generally Resources (Labors & Components) will be planned on Planning plant. Maintenance 1000 Maintenance Planning 1000 Description Dawn Foods – MPP SAP PM – Organizational Structure Company Code 1000 Maintenance Planning Plant 1000 MaintenanceMaintenance Plant 1000 Plant 1001 Maintenance Plant 1002 Maintenance Planning Plant 1000 Maintenance Planning Plant 1001 Maintenance Plant 1000 Maintenance Plant 1001 SAP PM - Technical Objects ■ Technical Objects & Master Data by definition is the data that remains unchanged over an Functional Locations extended period of time. Equipment BOM (Bill Of Material) Work Centers Measuring Points/Counter Maintenance Catalog Task Lists SAP PM - Technical Objects SAP PM - Technical Objects Functional Location A functional location represents the place at which a maintenance task is to be performed or equipment are installed. Functional criteria Example: Pumping station, Boiler Area. Functional Process-related criteria Example: Structure Manufacturing Technical Boiling Area etc. Spatial criteria Example: Hall, Location etc. Spatial SAP PM - Technical Objects Functional Location The structure indicator determines the edit mask and the number of the hierarchy levels when create functional location structures.. The edit mask defines: • The total length of the functional location number. • The lengths of the individual blocks of the functional location number. • The characters allowed. SAP PM - Technical Objects Equipment • • The "Equipment" is an individual, physical object that is to be maintained as an autonomous unit. It can be installed in a technical system or part of a technical system. Pieces of equipment usually represent single objects (for example, pumps, motors, vehicles, etc.) o Management of individual data o Recording of maintenance tasks o Object-based recording of costs o Evaluation of technical data o Recording of usage times SAP PM - Technical Objects Transportation and Fleet Equipment • • Fleet objects include cars, trucks, trains, ships, building machinery and transport containers. A fleet object can be displayed as an equipment master record with fleet object-specific views. o Identification Data o Dimension Data o Transport Data o Task List data o Engine Data o Fuel and Lubrication data SAP PM - Technical Objects Bill of Material (BOM) A maintenance bill of material (BOM) is a complete, formally structured list of the components making up a technical object or an assembly. The list contains the object numbers of the individual components together with their quantity and unit of measure SAP PM - Technical Objects Work center The performing work centre usually represents one person or a group of people who perform the maintenance work in the operations of an order. Maintenance Work center example: o Electrical Maintenance o Boiler Maintenance o Mechanical Maintenance SAP PM - Technical Objects Measuring Point/Counter • • A measuring point is a physical or logical position for a technical object (as equipment) where a condition can be recorded A counter is a type of measuring point that accumulates performance based readings – Measuring points and counters are created for technical objects to record a condition for the technical object at a given point in time – Counters can be used in maintenance plans to schedule preventive maintenance Hours Temperature 100° C 60800 HR SAP PM - Technical Objects Maintenance Task list A sequence of individual maintenance activities which must be repeatedly performed . SAP PM - Technical Objects Maintenance Plan Maintenance plans describes the preventive maintenance and inspection tasks that are to performed for the technical objects to for their optimal function. TASK LIST + (Do this) MAINTENANCE PLAN EQUIP/FL = MAINTENANCE ITEM (On this) = SCHEDULE DATE (From this date) + MAINTENANCE ITEM SAP PM – Maintenance Business Process Corrective Maintenance Process Maintenance actions carried out to restore a defective item to a specified condition SAP PM – Maintenance Business Process Corrective Maintenance Process - Notification • • • Is the starting point for maintenance processing Used for coordination with plant maintenance Include important findings for later evaluations and history SAP PM – Maintenance Business Process Corrective Maintenance Process -Planning SAP PM – Maintenance Business Process Corrective Maintenance Process - Notification SAP PM – Maintenance Business Process Corrective Maintenance Process -Planning Maintenance Work Order is created based on notification or combination of notifications to • Plan the suitable operations • Plan the component list that contains different spare parts and materials required for executing the maintenance order • View Planned costs that are collected in the order after planning operations and materials SAP PM – Maintenance Business Process Corrective Maintenance Process – Stock Material Process SAP PM – Maintenance Business Process Corrective Maintenance Process – Non Stock Material Process SAP PM – Maintenance Business Process Corrective Maintenance Process – External Services SAP PM – Maintenance Business Process Corrective Maintenance Process – Material Availability Check during Scheduling SAP PM – Maintenance Business Process Corrective Maintenance Process – Material Availability Check during Scheduling SAP PM – Maintenance Business Process Corrective Maintenance Process - Execution SAP PM – Maintenance Business Process Corrective Maintenance Process - Execution • • • Order is released for Execution Both Planned and Unplanned Issuance of materials from the warehouse to perform maintenance tasks The maintenance technicians execute the maintenance tasks SAP PM – Maintenance Business Process Corrective Maintenance Process – Time Confirmation SAP PM – Maintenance Business Process Corrective Maintenance Process – Time Confirmation • • • • The The The The maintenance task has been technically completed actual working times are entered in the operation time confirmation activities, damage, and causes of damage entered in the technical confirmation order and notification are then completed SAP PM – Maintenance Business Process Corrective Maintenance Process – External Process SAP PM – Maintenance Business Process Breakdown Maintenance Process SAP PM – Maintenance Business Process Preventive Maintenance Process SAP PM – Maintenance Business Process Preventive Maintenance Process Preventive maintenance work may be due to legal regulations, environmental protection requirements, manufacturer recommendations, or it is executed for reasons of quality assurance. Preventive Maintenance Time-based Performance-based Condition-based 2002 30 40 50 60 20 10 70 80 Printi ng Temperature Printing Thickness SAP PM – Maintenance Business Process Preventive Maintenance Process – Maintenance Plan and Strategy SAP PM – Maintenance Business Process Preventive Maintenance Process – Single Cycle SAP PM – Maintenance Business Process Preventive Maintenance Process – Strategy Based SAP PM – Maintenance Business Process Preventive Maintenance Process – Strategy Based SAP PM – Maintenance Business Process Calibration Process • • • An inspection with reference to calibration and adjustment. When a piece of measuring equipment is calibrated, the systematic deviation in measurements is determined based on predefined conditions of use, without actively changing the set up of the equipment. When the equipment is adjusted, the systematic deviation in measurements is corrected as required for its use. PM QM THANK YOU
