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Presentation Title | Confidential | Document D | 12-Nov-11 2
PLANT MAINTENANCE SYSTEM
SAP R/3
I. MANAGING MASTERS
II. MANAGING MAINTENANCE PROCESSES
III. MANAGING REPORTS
PLANT MAINTENANCE SYSTEM
I. MANAGING MASTERS
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
CONTENTS OF MAINTENANCE
OF MASTERS
Plant
Main Planner Group
Plant Section
Main Work Center
Cost Center /nternal Order
Category
Company Code
Strategy
UOM
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
CONTENTS OF MAINTENANCE
OF MASTERS
Function Location
Structure
Function Location Category
Plant
Functional locations Structure is a hierarchical Presentation of a Tech.
System.
Gives information about how the Technical System is sub divided into
Individual Functional Units.
Individual function Units are defined on the Basis of Process Orientation,
Functions, or any other Special criteria.
Each functional location is managed independently in the system, so that
you can :
W anage individual data from a maintenance perspective for the object
W Perform individual maintenance tasks for the object
W Keep a record of the maintenance tasks performed for the object
W Collect and evaluate data over a long period of time for the object
FUNCTIONAL LOCATION STRUCTURE
FUNCTION LOCATION STRUCTURE
Description Code
Structure ndicator GL
Structure ndicator Text GL Cement Division
Edit Mask AAA-AANN-AAX-AAX-XXX-XXXXX
Hierarchy Levels 1 2 3 4 5 6
Hierarchy
LeveI
Edit Mask Code Description
Level 1 AAA GL Grasim ndustries Limited
Level 2 AANN RC01 Raja shree Cement
Level 3 AAX RC1 Raja shree Cement Unit-
Level 4 AAX CM1 RC1 Cement Mill-1
Level 5 XXX FEG RC1 Cement Mill -1 Feeding
Group
Level 6 XXXX
ExampIe
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
CONTENTS OF FUNCTIONAL
LOCATION MASTER
Function Location Structure
Function Location Category
PIant
FUNCTION LOCATION CATEGORY
Category Description
C Colony Functional Locations
G General Functional Locations
H Hierarchical
M Plant & Machinery F Locations
N Mines Functional Locations
O Office Functional Locations
T Power Generation F. Locations
U Utility Functional Locations
DispIay of Function Location-[IL03]
List Editing of Function Location-[IH06]
DispIay ( MuIti LeveI) Function Location[IL07]
DISPLAY CONTENTS:
DispIay Action Log
Object Information
NAVIGATE > SAP SCREEN
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
BASIC CONTENTS OF MAINTENANCE
OF EQPT MASTER
Equipment Category
PIant
FunctionaI Location
Main PIanner Group
Tech. Object Type
PIant Section
Main Work Center
Cost Center /InternaI Order
Company Code
CIass
Warranty data
Defining Equipment Categories is a faciIity in SAP/PM to
group the vast variety of Equipments that any manufacturing
Organization can have in their PIant. One of the methods of
grouping simiIar Equipments is to differentiate them on the
basis of their Use and / or the Function that they perform e.g.,
EIectricaI Equipment. In GIL, this is the basis of defining
Equipment Category shown in the next two sIides
EQUIPMENT CATEGORY
CATEGO
RY
EQUIPMENT EXAMPLES
A AUTOMOBILE CARS/JEEP/MOBILE VAN
C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS
D DUMMY EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR
TRANSFER. NOT TO BE USED
E ELECTRICAL EQUIPMENTS MOTORS/TRANSFORMERS/SWITCH
GEARS
I INSTRUMENT EQUIPMENTS RTD'S/PROXIMITY SWITCHES/FIELD
INSTRUMENTS/PANELS
M MECHANICAL EQUIPMENTS GEAR BOXES/DPC/DBC/BELT
CONVEYORS
N MINES EQUIPMENTS SHOVELS/DUMPERS/DRILLING
MACHINES
EQUIPMENT CATEGORY
CATEGOR
Y
EQUIPMENT EXAMPLES
P PROCESS EQUIPMENTS CYCLONES/HOPPERS
Q QC TEST EQUIPMENTS CUBE TESTING MACHINE /
COMPRESSIVE STR MACHINE
R PRODUCTION RESOURCES/TOOLS CRANES
T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER
U UTILITY EQUIPMENTS COMPRESSOR/WATER PUMPS
NOTE:
ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO
TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT CONVEYORS
WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.
EQUIPMENT CATEGORY
EQUIPMENTS CATEGORY & NUMBER RANGE
Categor
y
Description
Number range
From
Number
Range
To
M MechanicaI Equipments 10000000 19999999
E EIectricaI Equipments 20000000 29999999
I Instrumentation Equipments 30000000 39999999
P Process Equipments 40000000 49999999
T TPP & DG Equipments 50000000 59999999
N Mines Equipments 60000000 69999999
A AutomobiIes Equipments 70000000 79999999
C CiviI Objects & GeneraI Equipt. 80000000 89999999
S Safety Equipments 90000000 99999999
Q QC Test Equipments 1000000 1999999
TechnicaI Object Types are the IogicaI grouping of Objects on the
basis of simiIarity of function being performed by each one.
ExampIes :
ME_GEARBOX Gear Box
EL_MOTORS EIectricaI Motors
ME_FANS Fans
TECHNICAL OBJECT TYPE
PIant in which maintenance tasks are pIanned and executed. In GIL ,
PIanning PIant is aIso a Maintenance PIant. Different PIanning PIants in GIL
are :
Aditya Cement
Grasim Cement
Vikram Cement
Rajashree Cement
Grasim South
BirIa Super Cement (Hotgi)
BirIa PIus Cement (Bhatinda)
PLANNING PLANT
MAIN WORK CENTER
Main Work Center is LogicaI Grouping of aII Work Centers, which are
Performing simiIar nature of Maintenance Tasks/Activities in different
PIant Sections. E.G. MechanicaI Main Work Center is a Group of PIant
Maintenance Persons, who are executing MechanicaI Maintenance
activities . Different Main Work Centers defined are :
MechanicaI Department
EIectricaI Department.
Instrumentation Department.
Process Department.
CiviI Department, Etc.
PIant Section is a division of Maintenance PIants into Production
Areas.
PLANT SECTION
Description Category PIant
Packing PIant -1 PP1
GC01
Cement MiII -1 CM1
GC01
KiIn -1 KL1
GC01
CoaI MiII -1 CO1
GC01
Raw MiII -1 RM1
GC01
PLANNER GROUP
Planner Group defines the Group of People (Employees) responsible
for Planning and Execution of Maintenance Activities in a Particular
Plant.
PLANNER GROUP CODIFICATION LOGIC
PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION
MCM = MechanicaI + Cement MiII
ECM = EIectricaI + Cement MiII
ICM = Instrumentation + Cement MiII
COST CENTER/ INTERNAL ORDERS
Cost Centers are IogicaI OrganizationaI Units where the costs are
incurred for vaIue addition . Costs incurred are uItimateIy settIed to Cost
Centers through Orders.
InternaI order is nothing but an intermediate cost coIIector between PM
order and cost center. InternaI Order wiII be used in Mines Equipment
onIy.
Cost Center Concept as appIied in GIL :
PIant Section = Superior Cost Center
Department = Sub Cost Center in that PIant section
CEMENT MILL
MechanicaI Process EIectricaI Instrumentation
Creation of Equipment-[E01]
Change of Equipment-[E02]
Display of Equipment-[E03]
List Editing of Equipment-[H08]
Display ( Multi Level)-[E07]
DISPLAY CONTENTS:
Display of Usage List
Display Action Log
Display Object nformation
nstallation & Dismantle
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
BASIC CONTENTS OF CLASS &
CHARACTERISTICS MASTERS
CIass Type
CIass Group
Characteristics Group
Unit of Measure for
Characteristics Master
CIasses are :
LogicaI Grouping of Equipments having SimiIar Functions.
CIass MainIy Depends on the Main Function / Activity being
Performed by that Equipment.
It heIps to know the Number of Equipments having the same
CIass.
CIass data wiII never Change throughout the entire Productive
Life-CycIe of the Equipment.
This information can be used for Proper PIanning of Spares,
for pIanned Maintenance & obtaining the History of that CIass
of Equipments.
CLASS
Characteristics are the Specifications or Designed Parameters of
Measurement for the Equipments. Ex. FIow of Fan , Gear Ratio of Gear
Box.
Combination of CIass and Characteristics heIps in Precise search of
Equipments.
For ExampIe:
SeIect Gearbox of ParticuIar Make / Ratio.
SeIect CIass as Gearbox & Characteristics as Make/ Ratio. Enter
ReIevant VaIues of these Characteristics.
System wiII search & dispIay aII Gearboxes satisfying above
Characteristics VaIues
CHARACTERISTICS
CLASS
CIass Description
GEARBOX GEARBOX
BUCKETELELVATOR BUCKET ELELVATOR
BALLMLL BALL MLL
BAGHOUSE BAG HOUSE
CIass Description
LTMOTOR LT MOTOR
LTFEEDER LT FEEDER
BATTERY BATTERY
BREAKER BREAKER
MechanicaI
EIectricaI
CLASS AND CHARACTERISTICS GROUPS CODES
CIass Group Code Description
PM_EQ_ELEC PM Elec. Equipments Specs. Class Group
PM_EQ_GENL PM General Equip. Specs. Class Group
PM_EQ_NST PM nst. Equipments Specs. Class Group
PM_EQ_MECH PM Mech. Equipments Specs. Class Group
PM_EQ_MNE PM Mine. Equipments Specs. Class Group
PM_EQ_PROC PM Proc. Equipments Specs. Class Group
PM_EQ_TPDG PM TPP & DG Equip. Specs. Class Group
SA_EQ_SAFE PM Safety Equip. Specs. Class Group
Char. Group Code Description
PM_EQ_ELEC PM Elec. Equipments Specs.Char. Group
PM_EQ_GENL PM General Equip. Specs. Class Group
PM_EQ_NST PM nst. Equipments Specs.Char. Group
PM_EQ_MECH PM Mech. Equipments Specs.Char. Group
PM_EQ_MNE PM Mine. Equipments Specs.Char. Group
PM_EQ_PROC PM Proc. Equipments Specs.Char. Group
PM_EQ_SAFE PM Safety Equip. Specs. Char Group
PM_EQ_TPDG PM TPP & DG Equip. Specs. Char. Group
DispIay of CIass List [CL03]
Find Object in CIass- [CL30N ]
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MIC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
BASIC CONTENTS OF MIC's MASTER
PIant
Range of Characteristics VaIue
MASTER INSPECTION CHARACTERISTCS
Specific parameters of an Equipment for Calibration
Parameters to measure whether Equipment is performing its function
The Parameter driving / governing Equipment performance/Output is
within acceptable limits.
Example: Mili-amperes / Mili-volts for weigh Feeder
Find out The Maintenance Inspection Characteristics prepared-[QS24]
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MIC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
BASIC CONTENTS OF WORK CENTER
MASTER
PIant
Work Center Category
ControI Key
Cost Center
Work Dimension - Time
Work Unit
WORK CENTER
Work Center is a Person/Group of Persons, who perform Maintenance Activities.
Work Center Category
Each Department wiII have two categories, Permanent and Contractor.
Category Description
0021 MechanicaI Permanent
0022 MechanicaI Contractor
ExampIe : M1F1W3K, MC1F1W3K etc.
Codification Logic :
M1F1W3K = Mech. Permanent / 1 Fitter /1WeIder / 3 KhaIasi
MC1F1W3K = Mech. Contractor / 1 Fitter /1WeIder / 3 KhaIasi
Work Center List-[IR03]
DISPLAY CONTENTS:
ReIevant Number for Permanent and Contractor Work centers
for your department.
Different combinations of SkiIIs.
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
BASIC CONTENTS OF MEASURING
POINT MASTER
Equipment Master
Function Location Master
Category of Measuring Point
Characteristics
Unit of Measures
t is a Measurement characteristic/Parameter attached to an Equipment
Describe the Physical and/or Logical Locations of Equipment
at which a Condition / Parameter is to be measured.
Measuring Point will be always for an Equipment or FL or assembly
but Generally for Equipments.
Measurement readings are taken for an Equipment at regular
interval to know the Condition at that time.
MEASURING POINT
Measuring Point is aIso Used as Counter where vaIues Measured
by a Measuring Point can be summed up during a time period for
monitoring and controI .
ExampIe:
Running hours of Any Equipment
Lubrication Consumption.
MEASURING POINT
Continued..
NAVIGATE > SAP SCREEN(MP)
Creation Of Measuring point [IK01 ]
Change / DispIay Of Measuring Point [IK02/ IK03]
DispIay List Editing-[IK07]
Create Entry List-[IK31]
CoIIective entry of measuring document-[IK34]
DSPLAY CONTENTS:
Transfer of Measuring point
MAINTENANCE MASTERS
BASIC MASTERS
1. Function Locations
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
BASIC CONTENTS OF TASK
LIST MASTERS
Group Coding
Counter
PIanning PIant
Maintenance Strategy
Work Center
Set of Operations
MI's
TASK LIST
A Set of Activities to be Performed on an Equipment or FunctionaI
Location.
Three types of Task Lists :
FunctionaI Location Task List[T]
Equipment Task List[E]
GeneraI Task List[A]
seq CodIIIcatIon LogIc Ior deIInIng Task LIst Group - It bas to be PIannIng PIant J MaIntenance SpecIIIc
1
GIL PIant Sbort Code:
RC = RC01, GS = GS01, GS = GS01, GC = GC01, BS = BS01.
2
IscIpIIne:
E = EIectrIcaI, M = MecbanIcaI, I =InstrumentatIon, P = Process, N = MInes, T = TPP,
Q = QC,S = SaIety
3
EquIpment Sbort "EquIpment CIass Code":
GB = Gear Box, BF= Bag FIIter, BC = BeIt Conveyor, AT = AnaIyzer, MO= C Motor, etc
4
EquIpment CIass Code Type( appIIcatIon) :
GB Gear Box HeIIcaI; RadIaI; BE-Bucket EIevator BeItJ CbaIn
5
Type oI MaIntenance Task LIst:
PM=PreventIve MaIntenance , AM = AMC Tasks, CA= CaIIbratIon ; S = Sbutdown , IN
= InspectIon (attrIbuteJVaIue EN-EnvIronment;) J-JIsbu Hozen ( GeneraI InspectIon ) 2-
SaIety
ExampIe: GCMGBHPM CCM-CDH-PM 1M CIccls
GCEMOPM CCE-Moior-DC-PM 3M CIccls
TASK LIST CODIFICATION
Set of Predefined Prefixed Time ntervals ( Called Packages) grouped
at Which Preventive Maintenance Activities can be taken Up.
These Maintenance Strategies can be selected By User to carry out
Maintenance Activities depending Upon :--
Age of Equipment
Design of Equipment
mportance of Equipment in Production Process
Maintenance Practices of Organization.
MAINTENANCE STRATEGY
GILDAY -- Frequencies Specified in GLDAY
Are 1W / 2W / 1M / 3M / 6M / 1Y
GILMON-- Frequencies Specified in GLMON
Are 6M/ 1Y/ 2Y/ 5Y
MINEHR -- Frequencies Specified in MNEHR
Are 100HR/ 300HR / 350HR/ 400HR
PERFHR -- Frequencies Specified in PERFHR
Are150HR / 250HR / 500HR/ 1000H
MAINTENANCE STRATEGIES
Continued..
GILDAY: Strategy is Used for Frequencies of Check Up to 6M.
GILMON: Strategy is Used for Frequencies of Checks More than 6M.
MINEHR: Strategy is Used For MINES Preventive Maintenance PIanning.
PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance
PIanning.
APPLICATION:
Continued..
MAINTENANCE PACKAGE
Strategy GILDAY
CycIe Length UOM Maintenance CycIe Text CycIe Short Text
7 DAY WeekIy (1 Week ) 1W
14 DAY FortnightIy (2 Weeks ) 2W
28 DAY MonthIy ( 4 Weeks ) 1M
84 DAY QuarterIy ( 12 Weeks ) 3M
168 DAY HaIf yearIy ( 24 Weeks ) 6M
336 DAY YearIy ( 48 Weeks ) 1Y
Strategy GILMON
6 MON HaIf yearIy 6M
12 MON YearIy 1Y
24 MON 2 YearIy 2Y
48 MON 5 YearIy 5Y
Strategy MINEHR
96 HR 100 Running Hours ( 96 Hrs) P1
504 HR 500 Running Hours ( 504Hrs) P5
1008 HR 1000 Running Hours (1008 Hrs) P6
3000 HR 3000 Running Hours ( 3000 Hrs) 1P
MAINTENANCE PACKAGE
Continued..
Strategy PERFHR
Cycle Length UOM Maintenance Cycle Text Cycle Short Text
144 HR 150 Running Hours ( 144 Hrs.) P1
12096 HR 12000 Running Hours (12096 H) P8
16128 HR 16000 Running Hours ( 16128 H P9
24192 HR 24000 Running Hours ( 24192 H 1P
32256 HR 32000 Running Hours ( 32256 H 2P
Continued..
MAINTENANCE PACKAGE
DispIay Task List-[IA07]
List Editing Task List-[IA09]
DISPLAY CONTENT:
Find Task Lists in your PIanner group.
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
ITEM MASTER
Equipment /Function Location
Master
Task Iist Master
Strategy
Maintenance Item describe Preventive Maintenance Tasks
to be performed on an Equipment at Predefined IntervaI
Maintenance Item = Equipment + Task List with set of operations
with Maintenance Package
MAINTENANCE ITEM
MAINTENANCE MASTERS
BASIC MASTERS
2. Equipment Master
4. MC's
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance tem
9. Maintenance Plan
PLAN MASTER
Maintenance Item Master
Strategy
ScheduIing parameter
Maintenance PIan is the ScheduIing of Task List attached to an
Equipment (Maintenance Item ) on Time ScaIe ( According to
Factory CaIendar ) or Performance scaIe ( According to Counter
i.e. Number of Hours).
PIan = Maintenance Item + ScheduIing Parameters
MAINTENANCE PLAN
TOLERENCE: ( 50% )
It is the difference between pIanned date and TECO date ,given in %age for
deciding whether maintenance cycIe shouId be shifted or not, considering
the gap between pIanned date and TECO date.
Shift factor wiII be effective onIy if difference between pIanned date and
TECO date is more than 50% of smaIIest intervaI (smaIIest package) , either
+ or side. If difference between pIanned date and TECO date is Iess than
50% of smaIIest intervaI (smaIIest package) , there wiII be no shift. For
GILDAY , it wiII be + / - 3.5 days , as minimum frequency is 1w. For GILMON
it wiII be +/- 3 months as min freq is 6M.
SHIFT: 100% .
If condition given in ToIerance is true it wiII shift the maintenance cycIe by
: given shift % x difference between pIanned date and TECO date .i.e. ActuaI
deIay
MAINTENANCE SCHEDULING PARAMETER
It indicates that an advance intimation of pIanned maintenance wiII be
given by 0.5 x minimum frequency of strategy seIected through order
generation .
FOR GILDAY :
1W Being minimum frequency , you wiII get weekIy order 3.5 days
in advance if caII horizon is 50%.
CALL HORIZON 50%
MAINTENANCE SCHEDULING PARAMETER
Continued..
II. MANAGING MAINTENANCE PROCESSES
MAINTENANCE PROCESSES
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF MAINTENANCE
PROCESSES
Creation of Notification
Creation of Orders
Execution of Orders
Confirmation of Orders
Technical Confirmation of
Orders
Creation of Purchase Request
Creation of Purchase Orders
Service Entry Sheets
Creation of Measuring Points
& Measuring Documents
nstallation / De-installation of
Equipments
1. PREVENTIVE MAINTENANCE PROCESS
BASIC PROCESSES
5. Work shop Repair
7. Calibration
BASIC STEPS OF PREVENTIVE
MAINTENANCE PROCESS
Selection of Orders
Execution of Orders
Technical Completion of
Orders
PROCESSES
SeIection of Orders
Execution of Orders
Technical Completion of Orders
SeIection of Order
Go to T. Code - W39
Flag Outstanding & n process
check box
Enter Order Type PM01
Enter Maintenance Plant
Enter Planner group for Order
Execute by clicking
button
Order list of relevant section
Appears
Enter Period ( Date from..to
)
Enter Status exclusive in
Multiple Selection
Select from Drill Down
CRTD, CNF ,
TECO & CLSD
H/L TO ORDER TYPES
ORDER TYPES
PM01 --- PREVENTIVE MAINTENANCE ORDERS
These Orders are PIanned by SAP System
User can not generate PM Work Order for this Order Type externaIIy.
This Order type wiII heIp User to find out Cost of Preventive Maintenance
excIusiveIy for his PIant section/PIanner group.
User wiII be abIe to compare Cost Of Preventive Maintenance vis--vis
Breakdown and Shutdown Maintenance.
User wiII be abIe to judge the effectiveness of Preventive Maintenance PIans by
this Order Type.
Order Numbering is bIocked for this Order
User wiII get Preventive Maintenance Orders under Maintenance Activity Type -
PVM , AnnuaI Maintenance Contract Orders under Maintenance Activity Type -
AMC and Inspection Orders under Maintenance Activity Type INW
PM02: BREAKDOWN MAINTENANCE ORDERS
This Order Type is excIusiveIy for Breakdown registration of Equipments
This Order Type indicates UnpIanned stoppage in Production Process
In addition to consumption of Recourses Iike Men , Machine , MateriaI ,
Production Ioss is aIso associated with this type of Order .
User can further segregate the breakdowns of Equipments under Warranty /
Insurance from other Breakdowns.
PM03: SHUTDOWN MAINTENANCE ORDERS
This Order Type indicates
AnnuaI Shutdowns ( Maintenance Activity Type: SDM)
PIanned WeekIy,FortnightIy,MonthIy Stoppages ( Maintenance Act. Type : WFM)
Opportunity Based Maintenance (Maintenance Activity Type: OPP)
The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be
booked under MAT- SDM.
Continued..
ORDER TYPES
PM03: SHUTDOWN MAINTENANCE ORDERS
OnIy PIanned WeekIy,FortnightIy,MonthIy Stoppages wiII be booked under Maintenance
Activity Type - WFM
Other Maintenance jobs not pIanned but undertaken because of avaiIabiIity of Opportunity are
booked under MAT-OPP.
PM05: CALIBRATION MAINTENANCE ORDERS
This Order Type is appIicabIe for CaIibration of Equipments
These Orders are PIanned by System . However , User can aIso raise Order externaIIy , if
required for unpIanned CaIibration jobs.
This Order Type has MAT- CAL .
PM06 : CORRECTIVE MAINTENANCE ORDERS
The jobs covered under this Order Type are of 2 types:
Corrective Actions suggested under WHY-WHY AnaIysis to avoid recurrence of Breakdown wiII
be covered under Maintenance Type - WHY .
Continued..
ORDER TYPES
PM06 : CORRECTIVE MAINTENANCE ORDERS
Other Maintenance Jobs of Corrective Nature e.g. Maintenance Requests from other
departments , RemovaI of AbnormaIities/Defects, RemovaI of Unsafe Conditions where
Breakdown has not occurred wiII be covered under MAT- CRM
PM07 --- CONDITION BASED MAINTENANCE ORDERS
This Order Type is appIicabIe for jobs pIanned on the basis of Condition of Spares. E.g.
RepIacement of Worn Out Chain/ Worn-out Hammers etc
MID , being Condition Monitoring Department , wiII use this Order Type for advising repair /
repIacements on the basis of Condition E.g. Hardness/Thickness/Vibrations etc
PM08 --- GENERAL MAINTENANCE ORDERS
This Order Type is appIicabIe for UNDEFINED jobs NOT FALLING under above categories
and not reIated to Equipment. E.g. Leakage of Water Tap in Administration BuiIding garden.
These are of Minor nature Repair Jobs.
This Order Type shouId not be used unIess it satisfies above condition
Continued..
ORDER TYPES
PM09: REPAIR MAINTENANCE ORDERS
There are Four different Activity Types or jobs covered under this category. They are:
Work Shop jobs shouId be registered under MAT - RWS
Rewinding jobs shouId be registered under MAT - REW
Tyre Retreading jobs shouId be registered under MAT - RET
ExternaI Repair jobs shouId be registered under MAT - RVN
PM10: IMPROVEMENT/MODIFICATION ORDERS
AII jobs of Improvements and Modifications in Maintenance (ReIiabiIity
MTTR/MTBF/MaintainabiIity/AvaiIabiIity) are covered under Maintenance Activity Type - IMO
Suggestions given by ConsuItants/Experts/Other Units/ Other sources Iike
Websites, ManuaIs, Magazines etc are covered under Maintenance Activity Type - CON.
PM11: CAPEX/BLOCK ORDERS
AII Work Orders raised for Project Work are covered under this Order Type and MAT-
CAP
PM12 --- CIVIL MAINTENANCE ORDERS
AII Work Orders raised for CiviI Work E.g. BuiIding/ PIumbing/ Carpentry/ Painting/
Foundation
etc are covered under this Order Type and MAT-CIV
Continued..
ORDER TYPES
Order Type Description Order Activity Type
PM01 Preventive Maintenance Order PVM,AMC,INW
PM02 Breakdown Maintenance Order BDM,WAR,INS
PM03 Shutdown Maintenance Order SDM,OPP,WFM
PM05 CaIibration Order CAL
PM06 Corrective Maintenance Order CRM,WHY
PM07 Condition Based Maintenance CBM
PM08 GeneraI Maint Order GEN
PM09 Repairs Order RWS,RVN,RET,REW
PM10 Improvement/Modification Order IMO.CON
PM11 Capex / BIock order CAP
PM12 CiviI Maintenance Order CIV
QCAL QC Insp./ CaIibration Order CAL
MAINTENANCE ACTIVITY TYPES IN PM ORDERS
PROCESSES
SeIection of Orders
Execution of Orders
SeIection of Order
Go to T. Code - W39
check box
Execute by clicking
button
Appears
Enter Period ( Date from..to
)
Multiple Selection
CRTD, CNF ,
TECO & CLSD
H/L TO ORDER TYPES
PROCESSES
SeIection of Orders
Execution of Orders
Move to SAP Screen
Select desired order
PROCESSES
Selection of Orders
Execution of Orders
Go to Operation TAB and
Change operations etc if reqd
Select operation & Go to
Component TAB if Material
Required
Select required Component
Enter reqd Qty , tem category,
Storage Location & Batch
Enter number of Selected Order
Go to T. Code - W32
Release PM01 Type Selected
Order
Order status will be
changed to REL from
CRTD
Execution of Orders
Enter Start Date & Time
Come to Header data Tab
PROCESSES
Selection of Orders
Execution of Orders
End date & time will
be changed by system
Determine cost by clicking
Save the Order
Move to SAP Screen
Schedule Order by Clicking
PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Order
Go to T. Code W44
Select Header Menu
Confirmation
Select via operation Iist in
Confirmation Menu
Enter Order type
Enter Planner group
Selection of operation list
appears
Enter Plant
Enter Status Exclusive in Multi
Selection List
CRTD, CNF ,
TECO & CLSD
Enter Reference date
PROCESSES
Selection of Orders
Execution of Orders
All Planning data of operations
defaulted from relevant Orders
Flag Final confirmation, Clear all
Res & No remaining work
Enter Start Date & Time
Enter End Date & Time
Select All Operations
Click All Actual Data on Header
Tool bar
All relevant Orders with
Operations will be copied on
main screen
Enter Actual Work Center Qty
Execute by clicking button
PROCESSES
Selection of Orders
Execution of Orders
Enter Confirmation Text
System will calculate Actual
Duration
Save Confirmation by clicking
Move to SAP Screen
Enter Actual Duration
PROCESSES
Selection of Orders
Execution of Orders
TechnicaI CompIetion of
Orders
CRTD, REL ,
TECO & CLSD
Order
Go to T. Code - W32
Flag n process check box
Enter Period (Date fromto)
Multiple Selection
Selection of Order Screen
appeared
Execute by clicking
button
PROCESSES
Selection of Orders
Execution of Orders
TechnicaI Confirmation of
Orders
Click Settlement Rule button
Click Flag of Technical
Completion
Enter / change cost center &
give % if required
Order Main Header Screen
Opens
Appears
Select order and click
Enter Reference Date & Time
Click Enter Button
Order is Technically Completed
& System Status Changed to
TECO
Move to SAP Screen
2. BREAKDOWN MAINTENANCE PROCESS
BASIC PROCESSES
5. Work shop Repair
7. Calibration
BASIC STEPS OF BREAKDOWN
MAINTENANCE PROCESS
Creation of M2-Notification
SeIection of M2-Notification
Creation of PM02-Order
SeIection of Order
Execution of Orders
TechnicaI CompIetion of Orders
Execution & CompIetion of
Notification
Why-Why AnaIysis
BASIC STEPS OF
Selection of M2-Notification
Selection of Order
Execution of Orders
Execution & Completion of
Notification
Why-Why Analysis
Enter Notification Type
Do not Enter Notification
Number
Go to T. Code W21Create
Notification
Enter Notification Description
Enter Equipment / FL /
Assembly (as required)
Enter Reported By (Name)
Creation of M2 Notification
H/L TO N/F Types
System Generated
Notification Tab Screen Appears
Manual Process
Click Enter Button
M1 --- MAINTENANCE REQUEST
This Notification type indicates a request made by Customer department to his
SuppIier/Service Provider. E.g Request made by Raw MiII MechanicaI for repair of
Gear Box shaft on Workshop.
This incIudes aII types of jobs of Maintenance/Repair/Service requests made by User
on Service Provider EXCEPT MaIfunction/Breakdown.
M2 --- MALFUNCTION/BREAKDOWN
This Notification Type is excIusiveIy for information regarding Breakdown of
Equipments
This Notification is raised generaIIy by Production on reIevant Maintenance
Department as a FIR of UnpIanned stoppage in Production Process.
However , anybody can raise this Notification if it satisfies above condition.
NOTIFICATION TYPES
Continued..
M3 --- UNSAFE CONDITION/ACCIDENT
This Notification is an information from any department incIuding Safety
regarding prevaiIing Unsafe/ Hazardous Condition which is dangerous and may
cause damage to Property/Human being / Environment /Surroundings etc , to
the reIevant department responsibIe for such condition for necessary corrective
action.
M4 --- ABNORMALITY RECORD
This notification is raised to register 7 types of Basic Defects in Equipments.
These defects are reveaIed through DaiIy Check List/ Inspection/PIant Round
Satisfies the WCM requirement to monitor 7 type of basic defects which are
responsibIe for Breakdown , if not corrected in time.
NOTIFICATION TYPES
Continued..
M5: RECOMMENDATION/IMPROVEMENT
This Notification is generated by User for any improvement/deveIopment to be
impIemented .
The source for Improvement/Modification/DeveIopment in ReIiabiIity/ AvaiIabiIity
/MaintainabiIity may be WHY-WHY AnaIysis, Experts/ConsuItants
recommendation/Other Units/KIP's etc
The number of such Notifications wiII be an indicator of improvements done by
User
These notifications wiII give List of Improvements done by User which is required
by WCM or for sharing with other Units.
M6 --- WORK REQUEST-WORKSHOP
This notification is raised by User on workshop requesting its services for
Repair/Machining/RepIacement of Spares/AssembIy/Equipment etc.
Continued..
NOTIFICATION TYPES
M7: GENERAL NOTIFICATION.
Notification which does not faII in any of the conditions mentioned above may be
raised in this type.
This type of Notification shouId not be used as far as possibIe as it wiII affect
history/vitaI information about Equipments.
M8: MEASURING POINT ERROR
This notification is raised by the SAP system automaticaIIy whenever the
Parameter defined as a Measuring Point deviates from its Standard VaIue or goes
beyond its AcceptabIe PermissibIe VaIue.
Continued..
NOTIFICATION TYPES
Notification Types
Notification Type Description Number Ranges From -To
M1 Maintenance Request 1000000000 to 1999999999
M2 Malfunction, B/Down 2000000000 to 2999999999
M3 UnsafeCond./Accident 3000000000 to 3999999999
M4 Abnormality Record 4000000000 to 4999999999
M5 Recommendation 5000000000 to 5999999999
M6 Work Request- W.Shop 6000000000 to 6999999999
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
Number
Notification
H/L TO N/F Types
System Generated
Manual Process
Click Enter Button
All information Defaulted
from equipment master
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
Go To Location Data Tab
Release & Save the Notification
f Reqd Enter Long Text
Flag breakdown check box
Main Work center/ Planner
Group etc Defaulted & can be
Changed f Required
Naviaget >SAP Screen
n case of Main Plant, M2 Type
Notifications will be Generated
by System thru breakdown entry
made by CCR
Enter Code of STD TEXT
Attached
Popup Massage of warranty
Prompts
f equipment Under
warranty
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
Flag check box Outstanding or
n process (as Reqd)
Enter Notification Date
Go to T. Code W28 Selection
of Notification
List of Notifications Appears as
per Selection Criteria
Select relevant Notification
SeIection of M2 Notification
Enter Planner group
Click Enter Button
Click on Details Button
Navigate. SAP Screen
Notification Change Screen
Appears
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
M2 Notification selected in
Changed Mode as explained in
pervious sheet
Further process of order will
remain same as explained in
process 1. Preventive
Maintenance
Enter PMActType BDM & click
continue button & save
Create Order Popup Screen
Appears with Defaulted data
from notification
Creation of PM02 Type Order
from Notification
Click Create button
of Order Tab
Breakdown Order Created
Navigate> SAP Screen
Process of Selection of Order,
Execution of Order, confirmation
& TECO will be similar to processes
explained in process
BASIC STEPS OF
SeIection of Order
Execution of Orders
Notification
Why-Why Analysis
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
M2 Notification selected in
Changed Mode as explained in
pervious Process
Next Popup screen Database
selection for SAP script text
On nsert Text screen Flag
Expand immediately , enter Text
D ST & click on dropdown of
Text Name field
nsert Text popup screen
appears.
Execution of M2 Notification
(Order not generated)
To Attach Std Text Go to Effect
field & select relevant code of
Std Text
Execute Popup screen
Database selection for SAP
script text without entering any
data
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
Select malfunction& downtime
tab and Enter down time end
Date &Time.
Desired Standard Text Get
copied in long text. Complete it
& go back to main screen
Now popup screen nsert Text
appear again with text attached.
Click Continue Button
Next Popup screen Find SAP
script text will appear. Select
relevant text & click continue
button
Click Complete Flag and
complete Notification
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why AnaIysis
Select status by flagging and
execute
Enter Date Range (From...To)
Go to T. Code -- ZRPM-WHY
Create Why Why AnaIysis
Sheet
Enter Plant , Plant Section &
Planner group
List of Notification appears (as
per selection criteria)
Select relevant notification &
double click it
Why Why Analysis screen
Appears
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why AnaIysis
Enter Observations
Flag YES box to actual Cause
Enter Object Code
Enter all Possible Causes
(Possible reasons)
Enter Analysis n Why Why
Field
Enter Rectification carried out
Enter Recommendations
Enter Damage Code
Enter Responsible person and
Tar Date for Recommendations
Select Document Attached - Say
2
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why AnaIysis
Change Why Why AnaIysis
Next procedure of Standard text
shall be similar as explained in
Process Execution of M2
Notification
Click Complete Flag and
Complete Notification
Save why-why Analysis
Go to Main screen of selected
Notifications why why analysis
Click Put in Process Flag
Change Why Why analysis data
as per requirement
Save changed why-why
Analysis
Go to T. Code ZRPM_WHY
3. SHUTDOWN MAINTENANCE PROCESS
BASIC PROCESSES
5. Work shop Repair
7. Calibration
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
SeIection of PM03 - Shutdown
Orders
Report of Shutdown PIanning
Creation of Direct Purchase
Order
Request (Indent)
Execution of Orders
Enter Equipment Number
Equipment selection screen
appears
Equipment Category - M
Enter plant Section
Enter Planner Group
Enter Order Type - PM03
Go to T. Code W31
MAINTENANCE PROCESS
Orders
Selection of PM03 - Shutdown
Orders
Report of Shutdown Planning
Order
Request (ndent)
Execution of Orders
Creation of Shutdown Order
Enter Equipment Class (Optional)
Maintenance Plant
Click Execute Button
By Drill Down go to
selection screen
MAINTENANCE PROCESS
Orders
Orders
Order
Request (ndent)
Execution of Orders
Enter Order Description
Go to Header data Tab & Enter
PMActTYPE - SDM
Enter Relevant Work Center
Select Desired Equipment &
click . Equipment entered in field
Go to Operation Tab and Enter
Operations as required
Enter Relevant Control key
Enter Planning Plant & Enter
Create Shutdown
Maintenance Order : Central
Header Screen appears
Pl Refer Next Slide
Better to Create Separate Order
for PMIN & PMEX Control key
Enter Cost Element & Press
Enter
Popup screen External
Processing Operation appears
Select Material Group ( S524
For External Services) & Pur.
Group
Go to service tab & Select
Desired Services from Service
Master or write Description only
& Enter Required Quantity
Select Operations
Activity type Defaulted
Select Operation & Go to
Component TAB if Material
Required
Enter WC Qty and Cal.Key
Enter Work or Duration
After Assigning ControI Keys
PMIN PMEX
Enter required Material, qty,
S.Loc (see stock) & Batch
Click Gen Data Button & Get
Reservation Number on comp
detail screen & come back
Click on External Button
External Processing operation
Appears
Enter Vender , tracking No &
click
Select
from Drill
Down
Again Go to Operation screen
Enhancement Button and enter
Field key ZPM0001, Position
Select
from Drill
Down
Select
from Drill
Down
Select
from Drill
Down
Select
from Drill
Down
For Release Order Press con
Save Order by click button
Click scheduling & determine
cost button
Create Purchase Requisition
screen appears. Enter Dept and
Press Enter
Enter Cost Element & Press
Enter
Repeat above three steps for
Next Operation's
Go to Header Screen & Click
Determine cost button
For Release Order Press con
Save order by click button
You can
See PR No
Thru GEN
data->Act
data Tab
MAINTENANCE PROCESS
Orders
SeIection of PM03 -
Shutdown Orders
Order
Request (ndent)
Execution of Orders
Orders
Process of Selection of
Order, Execution of Order,
confirmation & TECO will be
similar to processes
explained in process
MAINTENANCE PROCESS
Orders
Orders
Order
Request (ndent)
Execution of Orders
Enter Order type
Enter Main work center
Enter Plant Section
Enter Planner Group
Order
Go to T. Code W49N
Report1. of Shutdown
PIanning
Maintenance Plant
Display order & Operation:
selection of order & Operation
screen appears
Enter Period (dates)
MAINTENANCE PROCESS
Orders
Orders
Order
Request (ndent)
Execution of Orders
Report of Order with Operation
etc Appears
View Reports with Relevant
Layout selection
MAINTENANCE PROCESS
Creation of PM03 -Shutdown
Orders
Selection of PM03 -Shutdown
Orders
Order
Request (ndent)
Execution of Orders
Flag outstanding & n process
Click Multiple Selection of Order
Field
Enter Plant Section
Material availability nformation
screen
Go to WBK Material
Availability Check (for orders)
Report 2 of Shutdown
PIanning (MATERIAL)
Maintenance Plant
Enter Period (dates)
Enter Order Type- PM09
Click Multiple selection button
Enter Planner Group Select from Drill Down
MAINTENANCE PROCESS
Orders
Orders
Order
Request (ndent)
Execution of Orders
Paste Selected Orders &
execute
Screen of Availability list of
Materials for Operations will
appears
You will reach back to main
screen of Material availability
nformation
Go to back to Multiple selection
screen & Execute
Click execute button again
Report of Order with Operation
etc Appears
On This Screen You Will Get
Order wise Materials with Stock
Availability status
MAINTENANCE PROCESS
Orders
Orders
Order (For Contractors)
Request (ndent)
Execution of Orders
Go to T. Code ME21N Create
Purchase Order
Select Type of Purchase Order
Go to item overview Tab and
Enter Account Assignment K
and tem category - D
Enter Material Group , Plant ,
tracking number (Employee)
and Department (planner group)
Enter Vendor Code
Select from Drop Down
thru Vendors : Purchasing
Enter Purchase Organization,
Purchase Group & Company
Code
Enter Short text of Services
Select from Drop Down.
Search Tracking number
thru Vendor by Company
code
MAINTENANCE PROCESS
Orders
Orders
Request (ndent)
Execution of Orders
Go to Account Assignment Sub
Tab and Enter G/L Account
number and Cost center
Correct Entries f error massage
other wise Save the order
Check entries by Clicking Button
Go to tem Tab and Enter
Services number , Qty
BASIC PROCESSES
5. Work shop Repair
7. Calibration
MAINTENANCE PROCESS
Creation of Measuring Point
SeIection of Measuring Point
Creation of Measuring Document &
Auto Notification
Creation of Entry List
Measuring Document Thru Entry Iist
SeIection of M8 type Notification
Creation of Corrective Maintenance
Order Thru Notification
Execution of Orders
4. CONDITION BASE MAINTENANCE PROCESS
MAINTENANCE PROCESS
Orders
Orders
Request (Indent)
Execution of Orders
Requisition (For Spare)
Go to T. code ME51N -Create
PR
Enter PR Type & Header note
Account Assignment Type U &
tem Category leave Blank
Enter Material & Reqd Qty
Enter Del date , Plant &
Tracking number (planner
group)
Check entries by Clicking Button
Correct Entries f error massage
other wise Save the Purchase
request
BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Selection of Measuring Point
Creation of Measuring
Document & Auto notification
Measuring Document Thru
Entry list
Selection of M8 type
Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Orders
Select & enter Equipment
number
Select Relevant Measuring
Point Category (Except L & F)
Do not flag MP as counter for
CBM
Select Measuring Point Object -
EQ
Go to T. Code - K01 -Crete
Measuring Point
Click on Enter Button
Write Measuring Position &
Description
BASE MAINT. PROCESS
Entry list
Notification
Notification
Execution of Orders
Orders
Main screen appears. Now click
on Save button to save MP
Enter Upper range limit & Lower
range limit
Go to Additional data Button
header tool bar
Enter relevant Characteristic
(UOM & decimal Place
defaulted)
BASE MAINT. PROCESS
Entry list
Selection of M8 type Notification
Notification
Execution of Orders
Orders
Measuring point list appears
Select relevant Measuring point
Enter Characteristics & MP
Category
Go to T. Code - K07 Display
measuring Point : Measpoint
Selection
BASE MAINT. PROCESS
Document & Auto Notification
Entry list
Notification
Execution of Orders
Orders
Document
Enter MeasRdg as taken from
site
A Massage Appears n case
Reading is Outside range
Enter Measuring Point (as
selected)
Go to T. Code K11 - Crete
Measuring Document
Again Click on Enter Button
Main screen of M8 type
Notification Generates
Automatically
BASE MAINT. PROCESS
Document & Auto Notification
Entry list
Notification
Execution of Orders
Orders
A massage comes for
Measuring document Created
Enter Reported by & click Enter
button
An Auto Notification of M8 type
Created
BASE MAINT. PROCESS
Entry list
Notification
Notification
Execution of Orders
Orders
Screen of Measuring reading
entry list: Create Appears
Enter entry list name &
Description
Enter measuring point numbers
As selected from drop down list
All details of Measuring points
Appears in list
A Massage measurement
reading entry list xxx saved.
Go to T. Code K31 -
Measuring reading entry list:
Create
Now Click on Save Button
BASE MAINT. PROCESS
Entry Iist
Notification
Notification
Execution of Orders
Orders
Navigate>
SAP Screen
Enter Entry list number
ollective entry of
MeasDocuments: overview
screen Appears
Enter measuring Reading in
relevant measuring point field
Go to T. Code K34
Collective entry of
MeasDocuments: nitial screen
Document Thru Entry Iist
A Massage Appears n case
Reading is Outside range &click
again enter button. M8
Notification will generate
A massage appears as xx
Measuring document Created
5. REPAIR MAINTENANCE PROCESS
BASIC PROCESSES
5. Work shop Repair
7. Calibration
BASIC STEPS OF REPAIR
MAINTENANCE PROCESS
SeIection of Order
Execution of Orders
Notification
BASIC STEPS OF
Creation of M 6-Notification
Selection of M 6-Notification
Selection of Order
Execution of Orders
Notification
Number
Notification
H/L TO N/F Types
System Generated
Enter Code of STD TEXT
Attached
as per requirement
Manual Process
Click Enter Button
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Why-Why Analysis
Go To Location Data Tab
Save the Notification
Write Details of Job in Long Text
Main Work center/ Planner
Group etc Defaulted & can be
Changed f Required
All information Defaulted
from equipment master
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Flag check box Outstanding (as
reqd)
Enter Notification Date
Go to T. Code W28 Selection
of Notification
Select Notification & Create
PM09 Type Order
Click Create button
of Order Tab
SeIection of M6 Notification
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Select Relevant Work Center
(Type 0001)
Enter Number of Hours
Select Relevant Maintenance
Activity Type( Always RVN)
Other Field automatically
Populated.
Go to Operation TAB
Select Relevant Work Center for
Operator & Enter Number of
Hours
Go to Component TAB & Attach
Required Material
Create PM09 Type Order
BASIC STEPS OF
SeIection of Order
Execution of Orders
Notification
GO to W38 & Search PM09
Type Order
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Release Order & ssue Required
Material.
Carry out Repair Work As per
Request
BASIC STEPS OF
Selection of Order
Execution of Orders
Notification
Further process of order will
remain same as explained in
process 1. Preventive
Maintenance
6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC PROCESSES
5. Work shop Repair
6. ExternaI Repair/Services
7. Calibration
BASIC STEPS OF EXTERNAL REPAIR
MAINTENANCE PROCESS
SeIection PMEX Activity type
Creation of Purchase
Requisition
Creation Of Purchase Order
Confirmation of ExternaI
Service Entry Sheet
BASIC STEPS OF EXTERNAL
REPAIR PROCESSES
SeIection PMEX Activity type
Creation of Purchase Requisition
Creation of Purchase Order
Confirmation of External Service
Entry Sheet
Select Relevant Type
Maintenance Activity (Always
RVN, RWN)
Select Control Key As PMEX
Go to Operation TAB
Click External Service Button
Creation of PM09 Type Repair
Order
Enter Operation & Select t
POP Screen Will Appear Enter
Material Group S 524,Purchase
Group, Tracking Number
Enter & GO to External
Processing operation Screen
BASIC STEPS OF
Selection PMEX Activity type
Requisition
Entry Sheet
Write Short Text of External
Service , Approximate Cost of
Repair, Quantity & Unit
Enter Cost Element & click
Pop Screen of Purchase
request Will Appear Enter
Department (i.e Main Planner
group)
Go back to Order main screen
Release it & Save Order
Go to Change Mode of Order &
select TAB Actual Data You will
get PR number
Write Desired Vendor Code
BASIC STEPS OF
Requisition
Confirmation of External
Service Entry Sheet
Orders
GO TO Customer TAB & Enter
all Required Deatils
Go To Change Mode of PR
(ME52N)
GO To Document Overview &
Select Relevant PR
Save PR
MM Will Prepare Purchase Order
on PR
BASIC STEPS OF
Entry Sheet
MM Will Prepare Service Entry Sheet
You will Accept Service Entry Sheet
BASIC STEPS OF
Confirmation of ExternaI Service
Entry Sheet
This Type of Order to be TECO
only When FNAL Service Sheet
Made.
BASIC STEPS OF
Entry Sheet
Save
III. MANAGING REPORTS
STANDARD REPORTS
1. Object CIass Statistics [MCI1]
Object breakdown anaIysis in terms of Maintenance cost
Standard driII down (Key Figure)
AssembIy
Construction year
Manufacturer
MateriaI
Object cIass
Month
2. Manufacturer AnaIysis [MCI2]
Manufacturer wise.
AssembIy
Construction year
Manufacturer
MateriaI
Object cIass
Month
STANDARD REPORTS
3. Location AnaIysis [MCI3]
Location wise
AssembIy
Equipment
FunctionaI Location
Location
Maintenance pIant
PIanner group
PIanning pIant
PIant section
Month
STANDARD REPORTS
4. PIanner Group AnaIysis [MCI4]
PIanner Group wise
AssembIy
Equipment
FunctionaI Location
Location
Maintenance pIant
PIanner group
PIanning pIant
PIant section
Month
STANDARD REPORTS
5. SingIe Object - Damage AnaIysis [MCI5]
Object Damage anaIysis in terms of Damage & Causes,
Notification Type wise
Activity code
Cause of damage
CdGrp: damage cause
Code group: activity
Code group: damage
Damage
Equipment
FunctionaI Location
Notification type
Month
STANDARD REPORTS
6. Object Statistics [MCI6]
This report provide the detaiI about the object statistics ( Iike
how many Equipment instaIIed on a Function Location)
Object cIass
Manufacturer
MateriaI
Construction year
Month
STANDARD REPORTS
7. Breakdown AnaIysis [MCI7]
This report provide the Breakdown AnaIysis information
(No. of B/D, MTTR, MTBR etc.).
Equipment
FunctionaI Location
Object cIass
Month
STANDARD REPORTS
8. Cost AnaIysis [MCI8]
This report provide the Breakdown AnaIysis information
( No. of B/D, MTTR, MTBR etc.).
Equipment
FunctionaI Location
Object cIass
Month
STANDARD REPORTS
9. MTTR/MTBR Equipment [MCJB]
This report provide :
MTTR/MTBR AnaIysis Equipment wise( No. of B/D, MTTR, MTBR
etc.).
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)
STANDARD REPORTS
10. MTTR/MTBR FunctionaI Location [MCJC]
This report provide :
MTTR/MTBR AnaIysis Equipment wise
( No. of B/D, MTTR, MTBR etc.)
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)
STANDARD REPORTS
6.2 LIST OF DEVELOPED REPORTS
The following are the Reports that are being developed in SAP:
LIST OF DEVELOPED REPORTS:
S. No. PLANT REPORTS
1 List of Damage & Cause - Summary Report (Equipment wise)
2 Breakdown Matrix - Equipment ABC indicator & breakdown category wise
3 Work Center / Equipment wise MateriaI Consumption
4 Equipment ScheduIe Maintenance Report
5 Breakdown why-why AnaIysis Report
6 PM order Skipped / RescheduIed Report
7 PM Order SIippage Summary Report ( ScheduIe Maintenance SIippage in
PIant VC)
8 Preventive Maintenance Work Request Report
9 Motor FaiIure Report
10 Inspection Check List
S. No. PLANT REPORTS
11 Maintenance Order / Operation Pending List
12 Section / Equipment Performance Report
13 Equipment Lubrication Consumption Report
14 QuarterIy Lubrication Consumption Report
15 Purchase Request Tracking Report
16 Equipment Maintenance Cost Report
17 List of Service Entry Sheets
18 Work Center Wise Service Cost Report
19 Shutdown (consoIidated) PIanning Report (resources & cost)
S.No. MINES REPORTS
20 Tyre Life Summary Report
21 Equipment Position Wise Tyre Run Report
22 Tyre Maintenance Register
23 OiI Consumption Report
24 OiI, FiIter & Lubricant Monitoring Report
25 AssembIy Life DetaiIs
26 Sub assembIy Performance Report
27 Breakdown Summary
Select Equipment
Select Relevant Measuring Point Category
Flag for Measuring Point as a Counter
Write Measuring Position Description
Write Description of Measuring Point
Measuring Point Object
Attach Relevant CHARACTERSTCS
Crete Measuring Point- K01
CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1
Select From Drop
Down ,Always use
#UNNINGHOU#S
Enter Annual Estimate Reading
Press CON For Save
Message : Measuring Point . Created
Enter Counter Over Flow Reading
Press Enter CON
CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2
Maximum Reading of
Counter
t Will be drive Plan
THE END
Select Equipment
Flag for Measuring Point as a Counter
CREATION OF MESURING POINT (LUB/DieseI Consumption) Sheet 1/2
Always Select Category
L- for Lubrication &
F- FueI Consumption
Select From Drop
Down , ,Always LUB
CONCOSUMPTION..
Enter Save CON Button
Message : Measuring Point ..Created
Dont Enter Counter Over Flow Reading & Annual
Estimate Reading
Press Enter CON
CREATION OF MESURING POINT(LUB/DieseI Consumption) Sheet 2/2
The END
Estimate Reading
Press CON
Select Equipment
Press con
CREATION OF MESURING POINT Sheet 1/2
Select From Drop
Down
Estimate Reading
Press Enter CON
C#EATION OF ESU#ING POINT Sheet 2/2
THE END
Estimate Reading
Press CON
Enter CON Button Next Screen will Appear
for entering Reading
Enter Counter Reading or Difference of Counter
Select Desired Measuring Point
Creation of Measuring Document K11
C#EATION OF ESU#ING POINT DOCUENT (IK11)
Press CON Button For Save
Counter should be
GREATER than
Previous Reading or
Difference not more
than 24 Hours
Message : Measuring Document ..Created.
THE END
WITH
TIME BASED PACKAGE
Continued.. MAINTENANCE ITEM
Write Maintenance tem Description
Enter Equipment
Write ORDER Type
Maintenance Activity Type
Maintenance Plan Category
Attach Relevant Task List
Create Maintenance tem P04
CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04
This will be PM01
Always
(Use PVM Or AMC )
Select from Drop Down,
Use Always GLDAY &
GLMON Only
Flag General Task List
Press con , Screen will appear with List of Task
Lists
Select Appropriate Task List
Press con Enter
Press con for Save
Task List Display Screen will Appear on Screen
You will get Message : Maintenance tem ( System
Generated Number) Created. THE END
For Selection of Task List Use con
C#EATEING AINTENANCE ITE (TIE BASE) Sheet -2/2
WITH
PERFORMANCE BASED PACKAGE
MAINTENANCE ITEM
Write Maintenance tem Description
Enter Equipment
Write ORDER Type
Maintenance Activity Type
Maintenance Plan Category
Attach Relevant Task List
Create Maintenance tem P04
CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2
This will be PM01
Always
ALWAYS Use PERFHR
For Plant,TPP,DG
Equipment & MNHR
For Mines Equipment
Flag General Task List
Press Button , Screen will appear with Task List
Select Appropriate Task List
Press con
Press con for Save
Task List Display Screen will Appear on Screen
You will get Message : Maintenance tem ( System
Generated Number) Created
THE END
For Selection of Task List Use Button
C#EATE AINTENANCE ITE (PE#FO#ANCE BASE )Sheet -2/2
Creation of Maintenance Item-[IP04]
Maintenance Category
Press con
Write Maintenance Plan Short Description
Go to TAB For Assigning Maintenance tem
Maintenance Plan Number is System Generated
Number
POP Screen will appear
Message : Possible Deletion of Data Entered When
Selecting
Create Maintenance Plan (P01)
C#EATION OF AINTENANCE PLAN (TIE BASE) Sheet 1/3 IP01
,Always Use GLDAY &
GLMON
Main Planner Group ,Main Work Center & other field
automatically Populated
automatically Populated from Equipment Master
Press con
Go to TAB Maintenance PIan ScheduIing
Parameter
Write Scheduling Period :365 Days
Flag Fro Completion Requirement
Display Maintenance tem :Selection Criteria Screen
Will Appear ,Write Equipment Number & Press con
C#EATION OF AINTENANCE PLAN (TIE BASE) Sheet 2/3
Select Radio Button NO
Press con
Message will Appear on Screen : Maintenance Plan
.Created
The End
Pop Screen Will Appear For START DATE
Press con For Save
C#EATION OF AINTENANCE PLAN (TIE BASE) Sheet 3/3
Maintenance Category
Press con
Write Maintenance Plan Short Description & Enter
Counter
Go to TAB For Assigning Maintenance tem
Maintenance Plan Number is System Generated
Number
POP Screen will appear
Message : Possible Deletion of Data Entered When
Selecting
Create Maintenance Plan (P01)
C#EATION OF AINTENANCE PLAN (PE#FO#ANCE BASE) Sheet 1/3
,Always Select
PERFHR For Plant,
DG, TPP & MNHR
For Mines
automatically Populated
Press con
Go to TAB Maintenance PIan ScheduIing
Parameter
Write Scheduling Period :365 Days
Flag For Completion Requirement
Display Maintenance tem :Selection Criteria Screen
Will Appear ,Write Equipment Number & Press con
C#EATION OF AINTENANCE PLAN (PE#FO#ANCE) Sheet 2/3
Select Radio Button NO
Press con
Message will Appear on Screen : Maintenance Plan
.Created
The End
Pop Screen Will Appear For START Counter Reading
Press con For Save
C#EATION OF AINTENANCE PLAN (PE#FO#ANCE) Sheet 3/3

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