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

SAP AG

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

SAP AG

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

SAP AG

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).

SAP AG 1999

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
SAP AG 1999

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

SAP AG 1999

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

SAP AG 1999

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
SAP AG 1999

Plant Maintenance - Overview

Maintenance Work Centers

Maintenance work centers

For example:
Welding
Metalworking
Mechanics

SAP AG 1999

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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

SAP AG 1999

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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
SAP AG 1999

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Plant Maintenance - Overview

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

Spatial

Technical

Functional

Criteria
SAP AG 1999

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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?

SAP AG 1999

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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

SAP AG 1999

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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

SAP AG 1999

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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

SAP AG 1999

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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
SAP AG 1999

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Plant Maintenance - Overview

Bills of Material in Company

Production
bill of material

Maintenance
bill of material
SAP AG 1999

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.

SAP AG 1999

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Plant Maintenance - Overview

Business Process: Breakdown Maintenance

1
2

Notification

Planning
Scheduling

Execution
Execution

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
SAP AG 1999

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Plant Maintenance - Overview

Maintenance Order: Putting in Process

Status
'RELEASED'

Order papers
Put in process

SAP AG 1999

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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

SAP AG 1999

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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

SAP AG 1999

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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

Scheduling

Execution

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

SAP AG 1999

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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

SAP AG 1999

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Plant Maintenance - Overview

Maintenance Notification: Object Information

Orders
Notifications

Maintenance dates

Documents

Processing days

Object information

Links

Structure list
Breakdowns

SAP AG 1999

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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
SAP AG 1999

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Plant Maintenance - Overview

Print Maintenance Notifications

Maintenance
notification

Notification
overview

Fax transfer

Activity
report
Breakdown
report

SAP AG 1999

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Plant Maintenance - Overview

Cycle for Corrective Maintenance

1
2

Notification
Planning

Scheduling

Execution

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
SAP AG 1999

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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

SAP AG 1999

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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

SAP AG 1999

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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

Scheduling

Execution

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
SAP AG 1999

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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

SAP AG 1999

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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

SAP AG 1999

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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
SAP AG 1999

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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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