Plant Maintenance in SAP A Functional Perspective: by - Gopinath

18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.
0200
an award winning '2004 Future 50 Company'
Plant Maintenance in SAP
A functional perspective
By Gopinath
breaking through barriers to progress
SAP R/3 - Overview
SAP AG
R
Overview: R/3 Overview and Integration
R/3 R/3
Client / Server Client / Server
ABAP ABAP
CO CO
Controlling Controlling
AM AM
Asset Mgmt Asset Mgmt
PS PS
Project Project
System System
WF WF
Workflow Workflow
IS IS
I ndustry I ndustry
Solutions Solutions
HR HR
Human Human
Resources Resources
SD SD
Sales & Sales &
Di stribution Di stribution
PP PP
Production Production
Pl anni ng Planning
QM QM
Quality Quality
Mgmt Mgmt
FI FI
Financial Financial
Accounti ng Accounti ng
PM PM
Plant Main- Pl ant Main-
tenance tenance
MM MM
Materials Materials
Mgmt Mgmt
System-Wide Concepts
TeamSAP Academy
R/3 Overview &
Integration
R/3 Applications
Support & Services
Getting Started
2
3
Plant Maintenance - Overview
SAP AG
R
SAP R/3 Modules
Human Resources
Logistics Accounting
Cross Application
Functions
R/3 R/3
Client / Server Client / Server
ABAP ABAP
FI FI
Financial Financial
Accounting Accounting
CO CO
Controlling Controlling
TR TR
Treasury Treasury
PS PS
Project Project
System System
WF WF
Workflow Workflow
IS IS
Industry Industry
Solutions Solutions
MM MM
Material Material
Manag Manag. .
HR HR
Human Human
Resources. Resources.
SD SD
Sales & Sales &
Distrib Distrib. .
PP PP
Production Production
Planning Planning
QM QM
Quality Quality
Manag Manag. .
PM PM
Plant Plant
Maint Maint. .
4
SAP AG
R
SD
MM
PP
QA
PM
HR
FI
CO
AM
PS
WF
IS
R/3
What Is Integration?
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
5
SAP AG 1999
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).
Organization of Plant Maintenance:
Business Scenario
6
SAP AG 1999
Functional locations
Equipment
Assemblies
Bills of material
Networks of technical objects
Maintenance notifications
Maintenance orders
PMIS Plant Maintenance Information System
Maintenance work centers
EQM Technical Data
Task lists
Maintenance plans
PRM Preventive Maintenance
WOC Maintenance Processing
CRP Work Centers and Capacity
Structure of Plant Maintenance
7
SAP AG 1999
Concept of Plant Maintenance
Bills of material
Task lists
Characteristics
Classes
Equipment /
functional locations
Cost records
Cost center
Maintenance
work centers
Maintenance
notification
Material
reservation
Material
issues
Maintenance
order
Capacity
load
Time
confirmation
Purchase
requisition
Maintenance
strategies
Maintenance
plans
Master data
Planning
Order processing
Goods receipt /
invoice receipt
Purchase orders /
release order
8
SAP AG 1999
Organizational Structures in Plant Maintenance
General Organizational Units in Logistics
Location-Based Organizational Units
Planning-Based Organizational Units
Maintenance plant
For example, site,
building, coordinate
For example, production
area, plant engineer
Client
Maintenance
planning plant
Maintenance
work centers
For example, foreman,
work scheduling
For example, mechanics
Maintenance
planner groups
Plant section
Location
Plant
Company code
9
SAP AG 1999
Plant 1000
Cross-Plant Maintenance
Plant 1200 Plant 1300
Workshops
Workshops
Maintenance
requirement
Maintenance
requirement
Planning of
maintenance
requirements
Maintenance
requirement
Material
Warehouse
10
SAP AG 1999
Maintenance Work Centers
Maintenance work centers
For example:
Welding
Metalworking
Mechanics
11
SAP AG 1999
Work Center: Contents
Basic data
General data
Capacity data
Capacity categories
Scheduling
Capacity / pool capacity
Available capacity profile
T i m e
Links Links
Activity types
Staffing assignment
Staffing assignment
Activity types
Activity types
Work center
Person
Qualification
Staffing assignment
Cost center
12
SAP AG 1999
Work Center: Main Functions
Work Center
Work Center
Costing
data
Costing
data
Default values
for task lists
and orders
Default values
for task lists
and orders
Scheduling
data and
available capacity
Scheduling
data and
available capacity
10
11
Costing
Costing
2,724.00
1,200.00
124.00
4,048.00
2,724.00
1,200.00
124.00
4,048.00
Task list / order
Task list / order
Lead time
scheduling
Capacity planning
Lead time
scheduling
Capacity planning
13
SAP AG 1999
Technical
Functional
Spatial
Functional location = multi-level, hierarchical structure,
organized according to ...
Criteria
Functional Location
14
SAP AG 1999
Criteria for Functional Locations
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?
When is a functional location created?
15
SAP AG 1999
Automatic Assignment Upon Creation
C1-B
Biological
cleaning
C1 C1
Clarification Clarification
plant plant
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
16
SAP AG 1999
Example of Functional Location Structure
C1-B
Biological
cleaning
C1 C1
Clarification Clarification
plant plant
C1-M01-1
Reservoir
C1-M01-2
Ventilator
C1-M01-3
Sand
dredger
C1-M02-1
Reservoir
C1-M02-2
Ventilator
C1-M02-3
Fat
dredger
C1-B01-1
Pump 1
C1-B01-2
Pump 2
C1-B02-1
Ventilator
C1-B02-2
Filter
cell
C1-M
Mechanical
cleaning
C1-M01
Sand
trap
C1-B02-1A
Valve 1
C1-B02-1B
Valve 2
C1-B02-2A
Inlet
C1-B02-2B
Filtrate
level
C1-B02-2C
Outlet
C1-M02
Oil/fat
trap
C1-B01
Pump
plant
C1-B02
Filtering
station
C1-B02-2A/1
Valve 1
C1-B02-2A/2
Valve 2
C1-B02-2C/1
Valve 1
C1-B02-2C/2
Valve 2
17
SAP AG 1999
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
18
SAP AG 1999
Equipment Master Record
Equipment master record
Equipment master record
Internal note Internal note
Documents / Documents /
technical drawings technical drawings
Multilingual texts Multilingual texts
Equipment usage Equipment usage
Location A
Location B
Classification Classification
List
X
X
X
X
X
X
X
Address / partner Address / partner
Permits Permits
Measuring points / Measuring points /
counters counters
0 4 7 1
0 1 2 3
General
General
Location
Location
Organization
Organization
Structure
Structure
19
SAP AG 1999
Bills of Material in Company
Engineering/design
bill of material
Costing
bill of material
Maintenance
bill of material
Production
bill of material
20
SAP AG 1999
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.
21
SAP AG 1999
Notification
Notification
Planning
Planning
Scheduling
Scheduling
Execution
Execution
Completion
Completion
History
Material usage, orders, notifications, PMIS, usage list
History
Technical object
Description
Date
Malfunction
Work to be performed
Internal/external resources
Material
Tools
Capacity leveling
Availability check
Order release
Printout
Planned/unplanned material withdrawal
External procurement
1
4
4
5
5
2
2
3
3
1
2
2
3
3
Business Process: Breakdown Maintenance
Time confirmation
Technical completion
Order settlement
Technical confirmation
22
SAP AG 1999
Maintenance Order: Putting in Process
Status
'RELEASED'
Order papers
Put in process
23
SAP AG 1999
Time Confirmations
Initial screen
Partial confirmation
Final confirmation
Reversal option
Scope
Individual entry
Collective entry
Collective entry using operation list
Overall completion confirmation
24
SAP AG 1999
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
25
SAP AG 1999
Notification
Planning
Scheduling
Execution
Completion
History
Technical object
Description
Date
Malfunction
Material
Tools
Capacity leveling
Availability check
Order release
Printout
Time confirmation
Order settlement
4
5
2
3
1
Cycle for Corrective Maintenance
26
SAP AG 1999
Describes the condition of a maintenance object,
particularly a malfunction
Describes a maintenance activity already performed
(purely technical documentation)
Requests a maintenance service/task
Malfunction report
Activity report
Maintenance request
Definition of Maintenance Notification
27
SAP AG 1999
Date / time / reported by
Description
Object: Functional location
Equipment
Assembly
Material serial number
Location data
Breakdown / availability
Activity
Execution factors
Activities
Dates
Task description
Tasks
Damage location
Damage
Cause of damage
Text
Notification
items
Notification
Maintenance Notification: Structure
28
SAP AG 1999
i
i
Object information
Notifications
Maintenance dates
Documents
Links
Breakdowns
Structure list
Processing days
Orders
Maintenance Notification: Object Information
29
SAP AG 1999
Select Maintenance Notifications
Find particular maintenance notification
Process several maintenance
notifications simultaneously
Restrict planning worklist
Why ?
Different sorting
Select / delete complete list
Different list fields, internal display variant
Display breakdowns graphically
Excel processing
Scope
Selection conditions
Field selection
Customizing
Functions
Notification
Notification items
Tasks
30
SAP AG 1999
Print Maintenance Notifications
Maintenance
notification
Notification
overview
Breakdown
report
Activity
report
Fax transfer
31
SAP AG 1999
Notification
Scheduling
Execution
Completion
History
Technical object
Description
Date
Malfunction
Capacity leveling
Availability check
Order release
Printout
Time confirmation
Order settlement
4
5
3
1
Planning
Planning
Material
Tools
2
32
SAP AG 1999
Maintenance order / notification
Direct creation
of order
Maintenance
notification
Maintenance
order
Creation of order
based on notification
Maintenance
item
Maintenance
order
Automatic generation of
maintenance order
from maintenance item
Maintenance
notification
Maintenance
notification
Maintenance
notification
Maintenance
order
Combination of
maintenance notifications
for maintenance order
Maintenance
notification
Maintenance
order
Entry of order with
subsequent activity report
Creation of Maintenance Orders
33
SAP AG 1999
Flexibility of order processing
Execution
Period of validity
Object reference
Single object
Object list
Single order
Standing order
Internal processing
External processing
Characteristics of Maintenance Orders
34
SAP AG 1999
Component
assignment
Material
reservation
May May
Availability
check
Goods
issue
Printing
Order
release
Automatic
availability
check
May May
Stock Material - Process Flow
35
SAP AG 1999
Notification
Planning
Execution
Completion
History
Material
Tools
Technical object
Description
Date
Malfunction
Time confirmation
Order settlement
4
5
2
1
Scheduling
Scheduling
Capacity leveling
Availability check
Order release
Printout
3
3
36
SAP AG 1999
Stock
profile
Inward stock
movement
from purchase
order
Material withdrawal
for cost center
Inward stock movement
from internal production
Stock transfer
to other plant
Plant
stock
Today Requirement date
Safety
stock
Maximum
ATP quantity
Resource Planning: Availability Check
37
SAP AG 1999
Maintenance
order
Fax transfer
Job ticket
Operation
control ticket
Pick list
Material
withdrawal
slip
Confirmation
slip
Time ticket
Object list
Maintenance Order: Printing
38
SAP AG 1999
Times
Individual entry
Collective entry
Time sheet (CATS)
Activities
Activity reports
Confirmation texts
Object changes
Measurement readings
Order Completion Confirmation: Times / Activities
39
Questions ??
Contact Details :
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Cell : 469-879-4674
Residence : 972-444-8510

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18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.

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