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
FI
SD
Financial
Accounting
Sales
Sales &
Distribution
CO
MM
Materials
Materials
PP Mgmt
Production
Planning
Planning
Controlling
AM
Asset Mgmt
Mgmt
R/3
PS
Client / Server Project
Quality
System
Mgmt
ABAP
PM
WF
QM
Plant
Plant Maintenance
Workflow
HR
IS
Human
Resources
Industry
Solutions
Support & Services
System-Wide Concepts
R
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Plant Maintenance - Overview
SAP R/3 Modules
FI
SD
Logistics
MM
PP
Controlling
Production
Planning
TR
R/3
QM
PM
Plant
Maint.
Maint.
Human Resources
CO
Material
Manag.
Manag.
Quality
Manag.
Manag.
Accounting
Financial
Accounting
Sales &
Distrib.
Distrib.
Treasury
Client / Server
ABAP
PS
Project
System
WF
Workflow
HR
IS
Human
Resources.
Industry
Solutions
Cross Application
Functions
R
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Plant Maintenance - Overview
What Is Integration?
SD
MM
PP
FI
CO
AM
R/3
QA
PM
HR
PS
WF
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
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Plant Maintenance - Overview
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 plantbased (decentralized) or cross-plant
(centralized).
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Plant Maintenance - Overview
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
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Plant Maintenance - Overview
Concept of Plant Maintenance
Master data
Characteristics
Classes
Equipment /
functional locations
Cost records
Cost center
Bills of material
Task lists
Maintenance
work centers
Maintenance
strategies
Planning
Maintenance
notification
Order processing
Material
reservation
Material
issues
Maintenance
plans
Maintenance
order
Capacity
load
Time
confirmation
Purchase
requisition
Purchase orders /
release order
Goods receipt /
invoice receipt
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Plant Maintenance - Overview
Organizational Structures in Plant Maintenance
General Organizational Units in Logistics
Client
Company code
Plant
Location-Based Organizational Units
Maintenance plant
Location
Plant section
For example, site,
building, coordinate
For example, production
area, plant engineer
Planning-Based Organizational Units
Maintenance
planning plant
Maintenance
planner groups
Maintenance
work centers
For example, foreman,
work scheduling
For example, mechanics
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Plant Maintenance - Overview
Cross-Plant Maintenance
Plant 1200
Plant 1300
Maintenance
requirement
Maintenance
requirement
Workshops
Warehouse
Plant 1000
Planning of
maintenance
requirements
Maintenance
requirement
Workshops
Material
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Plant Maintenance - Overview
Maintenance Work Centers
Maintenance work centers
For example:
Welding
Metalworking
Mechanics
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Plant Maintenance - Overview
Work Center: Contents
Basic data
General data
Capacity data
Capacity categories
Scheduling
Links
Capacity / pool capacity
Available capacity profile
Activity types
Activity types
Activity types
Cost center
Work center
Person
Staffing assignment
Staffing assignment
Qualification
Staffing assignment
Time
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Plant Maintenance - Overview
Work Center: Main Functions
Work
Work Center
Center
10
11
Default
Default values
values
for
for task
task lists
lists
and
and orders
orders
Costing
Costing
data
data
Scheduling
Scheduling
data
data and
and
available
available capacity
capacity
Task
Task list
list // order
order
Costing
Costing
Lead
Lead time
time
scheduling
scheduling
Capacity
Capacity planning
planning
2,724.00
2,724.00
1,200.00
1,200.00
124.00
124.00
4,048.00
4,048.00
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Plant Maintenance - Overview
Functional Location
Functional location = multi-level, hierarchical structure,
organized according to ...
Spatial
Technical
Functional
Criteria
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Plant Maintenance - Overview
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?
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Plant Maintenance - Overview
Automatic Assignment Upon Creation
Existing
functional
locations
C1
Clarification
plant
C1-M
Mechanical
cleaning
C1-M01
Sand
trap
New
functional
locations
C1-B
Biological
cleaning
C1-M02
Oil/fat
trap
C1-M01-2
C1-M01-2
Ventilator
Ventilator
C1-B01
Pump
plant
C1-M02-2
Ventilator
C1-B01-1
Pump 1
C1-B02
Filtering
station
C1-B02-2
Filter cell
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Plant Maintenance - Overview
Example of Functional Location Structure
C1
Clarification
plant
C1-M
Mechanical
cleaning
C1-M01
Sand
trap
C1-B
Biological
cleaning
C1-M02
Oil/fat
trap
C1-B01
Pump
plant
C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3
Sand
Fat
Reservoir Ventilator dredger Reservoir Ventilator dredger
C1-B02
Filtering
station
C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2
Filter
cell
Pump 1
Pump 2 Ventilator
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
Valve 1
Valve 2
C1-B02-2C/1 C1-B02-2C/2
Valve 1
Valve 2
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Plant Maintenance - Overview
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
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Plant Maintenance - Overview
Equipment Master Record
Location A
Equipment
Equipment master
master record
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
Structure
Measuring points /
counters
0471
0123
Permits
Internal note
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Plant Maintenance - Overview
Bills of Material in Company
Production
bill of material
Maintenance
bill of material
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Engineering/design
bill of material
Costing
bill of material
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Plant Maintenance - Overview
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.
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Plant Maintenance - Overview
Business Process: Breakdown Maintenance
1
2
Notification
1
3
Planning
Scheduling
4
2
Execution
Execution
5
3
Completion
• Technical object
• Description
• Date
• Malfunction
• Work to be performed
• Material
• Internal/external resources • Tools
• Order release
• Printout
• Capacity leveling
• Availability check
• Planned/unplanned material withdrawal
• External procurement
• Time confirmation
• Order settlement
• Technical completion • Technical confirmation
History
Material
Material usage,
usage, orders,
orders, notifications,
notifications, PMIS,
PMIS, usage
usage list
list
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Plant Maintenance - Overview
Maintenance Order: Putting in Process
Status
'RELEASED'
Order papers
Put in process
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Plant Maintenance - Overview
Time Confirmations
Initial screen
Individual entry
Collective entry
Collective entry using operation list
Overall completion confirmation
Scope
Partial confirmation
Final confirmation
Reversal option
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Plant Maintenance - Overview
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
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Plant Maintenance - Overview
Cycle for Corrective Maintenance
1
2
Notification
• Technical object
• Description
• Date
• Malfunction
• Work to be performed
• Material
• Internal/external resources • Tools
Planning
3
Scheduling
4
Execution
5
Completion
• Order release
• Printout
• Capacity leveling
• Availability check
• Planned/unplanned material withdrawal
• External procurement
• Time confirmation
• Order settlement
• Technical completion • Technical confirmation
History
Material usage, orders, notifications, PMIS, usage list
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Plant Maintenance - Overview
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
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Plant Maintenance - Overview
Maintenance Notification: Structure
Notification
Date / time / reported by
Description
Object:
Functional location
Equipment
Assembly
Material serial number
Location data
Breakdown / availability
Notification
Text
items
Activities
Tasks
Damage location
Damage
Cause of damage
Activity
Execution factors
Dates
Task description
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Plant Maintenance - Overview
Maintenance Notification: Object Information
Orders
Notifications
Maintenance dates
Documents
i
Processing days
Object information
Links
Structure list
Breakdowns
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Plant Maintenance - Overview
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
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Plant Maintenance - Overview
Print Maintenance Notifications
Maintenance
notification
Notification
overview
Fax transfer
Activity
report
Breakdown
report
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Plant Maintenance - Overview
Cycle for Corrective Maintenance
1
2
Notification
Planning
3
Scheduling
4
Execution
5
Completion
• Technical object
• Description
• Date
• Malfunction
• Work to be performed
• Internal/external resources
• Order release
• Printout
• Material
• Tools
• Capacity leveling
• Availability check
• Planned/unplanned material withdrawal
• External procurement
• Time confirmation
• Order settlement
• Technical completion • Technical confirmation
History
Material usage, orders, notifications, PMIS, usage list
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Plant Maintenance - Overview
Creation of Maintenance Orders
Direct creation
of order
Maintenance order / notification
Creation of order
based on notification
Maintenance
notification
Combination of
maintenance notifications
for maintenance order
Maintenance
order
Maintenance
notification
Maintenance
notification
Maintenance
order
Maintenance
notification
Entry of order with
subsequent activity report
Maintenance
order
Maintenance
notification
Automatic generation of
maintenance order
from maintenance item
Maintenance
item
Maintenance
order
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Plant Maintenance - Overview
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
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Plant Maintenance - Overview
Stock Material - Process Flow
Component
assignment
Material
reservation
Availability
May
check
Order
release
Printing
Automatic
availability
check
May
Goods
issue
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Plant Maintenance - Overview
Cycle for Corrective Maintenance
1
2
Notification
• Technical object
• Description
• Date
• Malfunction
• Work to be performed
• Material
• Internal/external resources • Tools
Planning
3
Scheduling
4
Execution
5
Completion
• Order release
• Printout
• Capacity leveling
• Availability check
• Planned/unplanned material withdrawal
• External procurement
• Time confirmation
• Order settlement
• Technical completion • Technical confirmation
History
Material usage, orders, notifications, PMIS, usage list
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Plant Maintenance - Overview
Resource Planning: Availability Check
Material withdrawal
for cost center
Plant
stock
Stock transfer
to other plant
Inward stock
movement
from purchase
order
Inward stock movement
from internal production
Maximum
ATP quantity
Stock
profile
Safety
stock
Today
Requirement date
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Plant Maintenance - Overview
Maintenance Order: Printing
Maintenance
order
Fax transfer
Job ticket
Material
withdrawal
Operation
control ticket
slip
Confirmation
Pick list
slip
Time ticket
Object list
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Plant Maintenance - Overview
Order Completion Confirmation: Times / Activities
Times
Individual entry
Collective entry
Overall completion confirmation
Time sheet (CATS)
Activities
Activity reports
Overall completion confirmation
Confirmation texts
Object changes
Measurement readings
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Plant Maintenance - Overview
•Questions ??
•Contact Details :
mail id : gthangavelu@darylflood.com
Cell : 469-879-4674
Residence : 972-444-8510
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