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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
Sales & Sales Distribution
Materials Materials PP Mgmt Production Planning Planning
Asset Mgmt Mgmt
PS Client / Server Project Quality System Mgmt ABAP PM WF QM
Plant MainPlant tenance Workflow
Support & Services System-Wide Concepts
© SAP AG
Plant Maintenance - Overview
SAP R/3 Modules
Sales & Distrib. Distrib. Material Manag. Manag.
Client / Server ABAP
Quality Manag. Manag.
Plant Maint. Maint.
Cross Application Functions
© SAP AG
Overview 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 SD MM PP QA PM HR FI CO AM PS WF R/3 IS Object and application linking and overall system communication R © SAP AG 4 .Plant Maintenance .
maintenance planning is either plantbased (decentralized) or cross-plant (centralized).Plant Maintenance . Depending on the company structure.Overview Organization of Plant Maintenance: Business Scenario Plant Maintenance is an integral part of the company and has numerous links to other enterprise areas. © SAP AG 1999 5 .
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 6 .Plant Maintenance .
Plant Maintenance .Overview Concept of Plant Maintenance Master data Characteristics Classes Cost records Cost center Maintenance work centers Bills of material Task lists Maintenance strategies Equipment / functional locations Planning Maintenance notification Maintenance plans Order processing Material reservation Material issues © SAP AG 1999 Maintenance order Capacity load Time confirmation Purchase requisition Purchase orders / release order Goods receipt / invoice receipt 7 .
work scheduling For example.Overview Organizational Structures in Plant Maintenance General Organizational Units in Logistics Client Company code Plant Location-Based Organizational Units Maintenance plant Location Plant section Planning-Based Organizational Units Maintenance planning plant Maintenance planner groups Maintenance work centers © SAP AG 1999 For example. site. mechanics 8 . building. plant engineer For example. foreman.Plant Maintenance . coordinate For example. production area.
Plant Maintenance .Overview Cross-Plant Maintenance Plant 1200 Maintenance requirement Plant 1300 Maintenance requirement Workshops Plant 1000 Planning of maintenance requirements Maintenance requirement Warehouse Workshops Material © SAP AG 1999 9 .
Overview Maintenance Work Centers Maintenance work centers For example: Welding Metalworking Mechanics © SAP AG 1999 10 .Plant Maintenance .
Plant Maintenance .Overview Work Center: Contents Basic data General data Capacity data Capacity categories Scheduling Capacity / pool capacity Available capacity profile Links Activity types Activity types Activity types Cost center Work center Person Staffing assignment Staffing assignment Qualification Staffing assignment Time © SAP AG 1999 11 .
00 124.200.048.048.Overview Work Center: Main Functions Work Center Work Center 11 10 Default values Default values for task lists for task lists and orders and orders Costing Costing data data Scheduling Scheduling data and data and available capacity available capacity Task list // order Task list order Costing Costing Lead time Lead time scheduling scheduling Capacity planning Capacity planning 2.00 1.Plant Maintenance .200.00 © SAP AG 1999 12 .724.00 2.00 1.00 124.00 4.724.00 4.
.Plant Maintenance . organized according to .Overview Functional Location Functional location = multi-level.. Spatial Technical Functional Criteria © SAP AG 1999 13 . hierarchical structure.
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 14 .
Overview Automatic Assignment Upon Creation Existing functional locations C1 Clarification plant C1-M Mechanical cleaning C1-B Biological cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station New functional locations C1-M01-2 C1-M01-2 Ventilator Ventilator C1-M02-2 Ventilator C1-B01-1 Pump 1 C1-B02-2 Filter cell © SAP AG 1999 15 .Plant Maintenance .
Overview Example of Functional Location Structure C1 Clarification plant C1-M Mechanical cleaning C1-B Biological cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station 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-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 16 .Plant Maintenance .
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 17 .
Overview Equipment Master Record Location A Equipment master record Equipment master record Equipment usage Classification Location B List X X X X X X X General General Location Location Documents / technical drawings Multilingual texts Organization Organization Structure Address / partner Measuring points / counters Permits Internal note 0471 0123 © SAP AG 1999 18 .Plant Maintenance .
Overview Bills of Material in Company Production bill of material Engineering/design bill of material Maintenance bill of material © SAP AG 1999 Costing bill of material 19 .Plant Maintenance .
the data required for the other business processes needs to entered quickly and easily so that the subsequent steps can be executed.Plant Maintenance . © SAP AG 1999 20 .Overview Breakdown Maintenance: Business Scenario For breakdown maintenance.
Plant Maintenance . orders. usage list Material usage. notifications. PMIS. PMIS. notifications. orders.Overview Business Process: Breakdown Maintenance 1 2 3 4 5 2 3 Notification • Technical object • Description • Date • Malfunction 1 Planning Scheduling Execution Execution • Work to be performed • Material • Internal/external resources • Tools • Order release • Printout • Capacity leveling • Availability check • Planned/unplanned material withdrawal • External procurement Completion • Time confirmation • Order settlement • Technical completion • Technical confirmation History Material usage. usage list © SAP AG 1999 21 .
Plant Maintenance .Overview Maintenance Order: Putting in Process Status 'RELEASED' Order papers Put in process © SAP AG 1999 22 .
Plant Maintenance .Overview Time Confirmations Initial screen Individual entry Collective entry Collective entry using operation list Overall completion confirmation Partial confirmation Final confirmation Scope Reversal option © SAP AG 1999 23 .
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 24 .Plant Maintenance .
PMIS.Overview Cycle for Corrective Maintenance 1 2 3 4 5 Notification Planning Scheduling 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 usage. orders. notifications.Plant Maintenance . usage list © SAP AG 1999 25 .
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 26 .Plant Maintenance .
Plant Maintenance .Overview Maintenance Notification: Structure Date / time / reported by Description Object: Functional location Equipment Assembly Material serial number Location data Breakdown / availability Notification Text items Damage location Damage Cause of damage Notification Activities Activity Execution factors Tasks Dates Task description © SAP AG 1999 27 .
Plant Maintenance .Overview Maintenance Notification: Object Information Orders Maintenance dates Notifications Documents i Processing days Object information Structure list Links Breakdowns © SAP AG 1999 28 .
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 29 .
Plant Maintenance .Overview Print Maintenance Notifications Maintenance notification Fax transfer Notification overview Breakdown report Activity report © SAP AG 1999 30 .
usage list © SAP AG 1999 31 . PMIS. notifications.Plant Maintenance . orders.Overview Cycle for Corrective Maintenance 1 2 3 4 5 Notification Planning • Technical object • Description • Date • Malfunction • Work to be performed • Internal/external resources • Material • Tools 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.
Overview Creation of Maintenance Orders Direct creation of order Creation of order based on notification Maintenance order / notification Maintenance notification Maintenance notification Maintenance notification Maintenance notification Maintenance order Maintenance item Maintenance order Combination of maintenance notifications for maintenance order Maintenance order Entry of order with subsequent activity report Automatic generation of maintenance order from maintenance item © SAP AG 1999 Maintenance notification Maintenance order 32 .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 33 .Plant Maintenance .
Overview Stock Material .Process Flow Component assignment Material reservation Order release Availability May check Printing Automatic availability check May Goods issue © SAP AG 1999 34 .Plant Maintenance .
notifications. PMIS. orders.Plant Maintenance .Overview Cycle for Corrective Maintenance 1 2 3 Notification Planning Scheduling • Technical object • Description • Date • Malfunction • Work to be performed • Material • Internal/external resources • Tools • Order release • Printout • Capacity leveling • Availability check 4 5 Execution Completion • Planned/unplanned material withdrawal • External procurement • Time confirmation • Order settlement • Technical completion • Technical confirmation History Material usage. usage list © SAP AG 1999 35 .
Overview Resource Planning: Availability Check Plant stock Material withdrawal for cost center 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 36 .Plant Maintenance .
Plant Maintenance .Overview Maintenance Order: Printing Maintenance order Job ticket Fax transfer Material Operation control ticket Pick list Time ticket Object list withdrawal slip Confirmation slip © SAP AG 1999 37 .
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 38 .Plant Maintenance .
com Cell : 469-879-4674 Residence : 972-444-8510 39 .Overview •Questions ?? •Contact Details : mail id : gthangavelu@darylflood.Plant Maintenance .
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