R/3-System

Release Enterprise 4.7

Author:

Stefan Kroeger
TPLM30

September 2003
Case Study

Plant Maintenance

Instructor Guide
 SAP AG TPLM30 Case Study

Contents:
SAP Contact(s)................................................................................................................. 3
Course Details .................................................................................................................. 3
Duration............................................................................................................................ 3
Course Materials and Other Materials ............................................................................... 3
Country-Specific Units ...................................................................................................... 3
Course Instructor Profile ................................................................................................... 3
Level of Knowledge Required ........................................................................................... 3
Training System................................................................................................................ 3
Work in IMG (Customizing) ............................................................................................... 3
User ID and Passwords for instructor ................................................................................ 3
User ID and Passwords for course participants ................................................................. 3
CATTs and Example ABAPs............................................................................................. 3
Technical Hints ................................................................................................................. 3
1. General Introduction ..................................................................................................... 3
2. Background information on Sport Motorcycle AG .......................................................... 3
3. Description of Sport Motorcycle AG Group .................................................................... 3
4. Basic Data in the System .............................................................................................. 3
5. Requirements in the Subject Areas ............................................................................... 3

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 SAP AG TPLM30 Case Study

SAP Contact(s)
Walldorf
Stefan Kroeger
Ruediger Keilbach
Michael Wieland

Course Details
Duration
5 days
Case Study – 4 days
Monday, 10.00 to 17.00
Tuesday - Thursday 9.00 to 17.00
Certification – 1 day
Friday – depending on local schedule

Course Materials and Other Materials

Manual for course particpants
Instructor guide
Instructor guides of standard courses PLM310, PLM315 and PLM316 can be used as a reference
for certain parts of the case study. They are available via SAPNet.

Country-Specific Units
None

Course Instructor Profile

Experienced instructor or consultant who is capable of teaching and demonstrating the complete scope
of SAP PM with its integration aspects.
Level of Knowledge Required
Instructor must be familiar with the following courses in detail:
PLM300, PLM305, PLM310, PLM315, PLM316
or as an alternative the corresponding courses of R/3 Rel. 4.6C:
LO100, LO805, LO810, LO815, LO816 plus Delta course D47PM
Also, the instructor must have detailed knowledge of the processes in Materials Management as the
integration between Plant Maintenance and Materials Management is one of the major topics of this
course.
Recommended courses for preparation:
SCM500, SCM510, SCM525, SCM550

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 SAP AG TPLM30 Case Study

Training System
Client
Only one client needed – all participants work in the same client
Data Required
Most data within Plant Maintenance will be created by participant during case study
Data within Materials Management required in Plant Maintenance (plants, storage locations,
materials, BOMs etc.) will be created by participant during case study
Data within Financial Accounting and Controlling (Controlling area, cost center, company code etc.)
will not be created by participant but rather used as offered by the IDES system. A hint is given for
every implementation step about which data to use.

Work in IMG (Customizing)

Execute report ZSENQOFF using transaction SE38 so that participants can work in IMG
simultaneously.

User ID and Passwords for instructor

Instructors should logon as user TPLM30 with password INIT. This user already exists in the master
system.

User ID and Passwords for course participants

Create users TPLM30-00 to TPLM30-20 for the course participants using transaction ZUSR (from
template user PM_TRAINING) with password INIT

CATTs and Example ABAPs

None

Technical Hints
None

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 SAP AG TPLM30 Case Study

Structure and Flow

The case study is structured into the following parts:

General introduction
Background information on Sport Motorcycle AG
Description of Sport Motorcycle AG Group
Basic data in the system
Requirements in the subject areas
Maintenance Organization
Management of Technical Objects
Maintenance Processing
Preventive Maintenance
Controlling in Plant Maintenance
Optional (Reporting and analyses)

Note:
As participants work as project teams – and therefore at their own pace – there is no fixed
schedule for the different steps within the case study.
However, all project teams must have finished their work until mid-day of day four so that
presentations can take place in the afternoon of day four.

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 SAP AG TPLM30 Case Study

Day One
Approximate Contents: Units and Topics
Times
Including
Exercises
30 min General Introduction
Background information concerning Sport Motorcycle Inc.

Start with implementation of requirements of Sport Motorcycle in the system

Days Two and Three

Approximate Contents: Units and Topics
Times
Including
Exercises
Implementation of requirements of Sport Motorcycle in the system - continued

Day Four
Approximate Contents: Units and Topics
Times
Including
Exercises
until mid-day Implementation of requirements of Sport Motorcycle in the system - continued

Presentations of project teams

Day Five
Approximate Contents: Units and Topics
Times
Including
Exercises
Certification

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 SAP AG TPLM30 Case Study

1. General Introduction

List of Topics in the Unit:

Presentation of the particpants and the instructor
(Previous experience with SAP and PM, expectations of the course and so on)
Breaks
Advice on parking
Training documentation
Course objectives

Course Objectives
The course has two objectives:
1. Prepare junior consultant for his/her later work within a case study that allows
him/her to set up business processes in plant maintenance according to customer
requirements
2. Prepare junior consultant for certification

2. Background information on Sport Motorcycle AG

In this unit participants receive general information about their future customer and
about the customer’s motivation to implement SAP Plant Maintenance.
The objective here is to put participants into a realistic context which is typical for
their future work as consultants.

3. Description of Sport Motorcycle AG Group

In this unit participants receive detailed information about the company’s structure in
general and about the specific requirements of maintenance organization.
This is meant to be the starting point for participants from where to analyze the
fundamental organizational requirements from a real life scenario and to “translate”
them into SAP objects and settings.

4. Basic Data in the System

In this unit participants receive fundamental organizational data that have already
been fixed and therefore do not have to be defined during the implementation of
SAP Plant Maintenance (these data are provided by the IDES system).
This simulates the situation in which project teams implementing SAP Plant
Maintenance often find themselves in: the customer already has introduced financial
accounting, controlling and materials management and therefore has already made a
decision about the major organizational units.
This is normally also true for the plants in manufacturing and materials management.

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SAP AG TPLM30 Case Study

However, as the plants play an important role in maintenance organization as well, it

is essential for PM consultants to be familiar with the handling of plants and storage
locations. Therefore they have not been predefined in this case study.

General

Controlling area 1000 EUROPE

Business area 1000 Mechanical engineering

Company code 1000 IDES AG

Purchasing organization: 1000 IDES Germany

Factory calendar 01 Germany

Plant Maintenance
Cost center for technical
4110 Technical assets
objects

Class for oil pumps ED113 (class type 002 – equipment class)

Serial number profiles PM1, PM2

Costing variant PM01

Costing sheet COPM

Materials Management

Material type HIBE (Operating Supplies)

Activate quantity and value update
Transaction OMS2
for material type
Activate valuation category C for
Transaction OMWC
each plant

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SAP AG TPLM30 Case Study

C1 - as new
Valuation types for refurbishment C2 - refurbished
C3 – defective

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 SAP AG TPLM30 Case Study

5. Requirements in the Subject Areas

In this unit participants will find the detailed requirements within the different areas
and business processes:
- Maintenance Organization
- Management of Technical Objects
- Maintenance Processing
- Preventive Maintenance
- Controlling
- Reporting (optional)

Maintenance Organization
In this section it is essential to define the necessary plants with the required settings
and practice again the relationship between maintenance plant and planning plant.
As the definition of plants and storage locations has mainly to do with materials
management, the required steps and settings are available to participants.
Also, it is essential that the required work centers are defined with the necessary
settings and are assigned to the right plant.

Objects to be Created – Organization

Plant I Hamburg-Lockstedt HL##

Plant II Hamburg-Wilhelmsburg HW##

Maintenance planner P##

Materials warehouse at plant I ML##

Mechanical workshop ME##

Electronics workshop EL##

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SAP AG TPLM30 Case Study

Objects to be Created – Technical Objects / Materials

Functional Location structure ?

Equipments ?

Coolant lubricant pump material KP##

Batches (valuation types) of coolant

C1, C2 and C3
pump KP## for split valuation

Spare parts DI-##, FL-##, AN-##

BOMs ?

Customizing Steps Required for Materials Management

Define storage location
Define quantity and value update
Define account determination
Maintain plant parameters for
inventory management
Enterprise Structure > Definition >
Materials Management > Maintain
Storage Location
Logistics – General > Material
Master > Basic Settings > Material
Types > Define Attributes of
Material Types
Materials Management >
Valuation and Account
Assignment > Account
Determination > Account
Determination Without Wizard >
Group Together Valuation Areas
(entry without valuation grouping
code)
Material Management > Inventory
Management and Physical
Inventory > Plant Parameters

The following list contains the sequence of steps for creating a new plant and a
new storage location as areference for the instructor.
As the creation of plants and storage locations is not part of the PM courses the
instructor can give hints to participants. However, this should not be
demonstrated from the start. Participants should rather work on this
requirement first.

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SAP AG TPLM30 Case Study

1. Define plants HL## and HW##

Enterprise Structure > Definition > Logistics – General > Define, copy, delete, check
plant
2. Maintain planning plant
Enterprise Structure > Definition > Plant Maintenance > Maintain maintenance
planning plant
3. Define storage location in plant HL##
Enterprise Structure > Definition > Materials Management > Maintain Storage
Location
4. Assign plant to company code
Enterprise Structure > Assignment > Logistics – General > Assign plant to company
code
5. Assign purchasing organization to plant
Enterprise Structure > Assignment > Materials Management > Assign purchasing
organization to company code
6. Assign standard purchasing organization to plant
Enterprise Structure > Assignment > Materials Management > Assign standard
purchasing organization to plant
7. Assign maintenance planning plant to maintenance plant
Enterprise Structure > Assignment > Plant Maintenance > Assign maintenance
planning plant to maintenance plant
8. Define quantity and value update (for material type HIBE in valuation
areas (=plants in this case) HL## and HW##)
Logistics – General > Material Master > Basic Settings > Material Types > Define
Attributes of Material Types
9. Define account determination > enter valuation grouping code 0001 for
valuation areas HL## and HW##
Materials Management > Valuation and Account Assignment > Account
Determination > Account Determination Without Wizard > Group Together
Valuation Areas
10. Maintain plant parameters for inventory management (use plant 1000
as a reference)
Material Management > Inventory Management and Physical Inventory > Plant
Parameters
11. Activate split valuation > split valuation by status (C) for both plants
Materials Management > Valuation and Account Assignment > Split Valuation >
Activate Split Valuation
12. Define plant parameters for MRP > copy parameters of plant 1000
Materials Management > Consumption-Based Planning > Plant Parameters > Carry
Out Overall Maintenance of Plant Parameters

Maintenance Organization - Technical Objects / Materials

Participants have to develop an appropriate structure consisting of functional
locations, equipments and BOMs to meet the requirements of Sport Motorcycle AG.
The structures created by participants are to be discussed during the presentations on

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SAP AG TPLM30 Case Study

day four. There is no model solution provided in the system.

Material KP## (Coolant pump)
Make sure the material is prepared for refurbishment already during the creation of
the material master. Enter valuation category C (status) into tab strip Accounting 1.
After saving the material master valuation types C1, C2 and C3 can be created by
adding material KP## again with tab strip Accounting 1 selected. Make sure you
bring up Organizational levels to be able to make an entry in the field valuation type
Availability check for coolant pump (KP00):
Make sure you enter a value for the availability check in the material master
(MRP3): either daily requirements (01) or individual requirements (02).
Goods receipt of coolant pump KP00:
In transaction MIGO, Goods receipt - Others can be used together with movement
type 501. Make sure you enter valuation type C1 on tab strip Material after you have
specified plant HL## and storage location ML##.

Hints for equipments created automatically during goods receipt:

- make sure to enter correct maintenance plant in equiment master
- if serial number profile PM2 is used in material KP00, equipment category Z is
predefined
- equipment category Z uses a user status profile where status PLA and status TST
do not allow installation of equipment into a functional location
>>change user status to PRD before trying to install equipment

Maintenance Processing
In this section maintenance processing has to be set up according to the requirements
of Sport Motorcycle. That means that notification processing as well as order
processing has to be defined.
The maintenance processing part consists of the following parts:
- create new notification type ##
- assign necessary paramters to new notification type ##
- create new order type IH##
- assign necessary paramters to new order type IH##
- make existing order type (PM04 - refurbishment) available in the new planning
plant
- complete parameters for order type PM04 in the new planning plant
If questions arise in this part, the instructor guide of standard course PLM315 can be
used as a reference.
In more detail, the following data have to be created by participants:

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SAP AG TPLM30 Case Study

Objects to be Created – Maintenance Processing

Notification type ##

Code group for internal damage S##

Code group for internal cause codes U##

Code group for internal object parts O##

Code group for internal activities

T##
(actions)

Internal catalog profile BS##

Order type IH##

Specific Customizing Steps - Maintenance Processing

Production > Shop Floor Control >
Integration > Define Valuation of
Goods Received
Define condition-valuation
(refurbishment) Entry in the new maintenance
planning plant with the same
valuation variant as that for plant
1000, 007)
Plant Maintenance and Customer
Service > Maintenance and Service
Processing > Maintenance and
Service Orders > Functions and
Documentation on goods movements Settings for Order Types > Goods
for the order Movement for Order > Define
Documentation for Goods
Movement for the Order
(Entries are similar to those for
order type PM04 in plant 1000)

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Maintenance Processing - Refurbishment

Hints for refürbishment:
- change master batch in serial number to C3 before executing transaction IE4N
(dismantling of equipment / moving to stock)
- assign oder type PM04 to planning plant HL##
- complete settings for order type PM04 and plant HL##: scheduling, costing
parameters, completion confirmation

Preventive Maintenance
In this section preventive maintenance has to be implemented according to the
requirements of Sport Motorcycle.
The central issue here is to properly schedule different maintenance plans.
In more detail, the following objects have to be created and the following
customizing steps have to be performed:

Objects to be created - Preventive Maintenance

General task list ?

Change number for task list ?

Time-based maintenance plan ?

Performance-based maintenance plan ?

Specific Customizing Steps - - Preventive Maintenance

Check / modify existing maintenance
?
plan categories

Define sort field ?

Define Default Order Types for

IH##
Maintenance Items

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SAP AG TPLM30 Case Study

Controlling in Maintenance
In this section the settings for costing and settlement of an order have to be made
according to the requirements of Sport Motorcycle.
This has to be done both for the new order type IH## as well as for order type PM04
(refurbishment).

Objects / Customizing steps - Controlling

Assignment cost elements - value
check / modify existing assignment
category
Costing variant order types IH##, check / modify existing variant or
PM04 create new one
Costing sheet order types IH##, check / modify existing costing
PM04 sheet or create new one
Default settlement rule order types
?
IH##, PM04
Settlemente profile order types IH##, check / modify existing profile or
PM04 create new one

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SAP AG TPLM30 Case Study

Optional (Reporting and Analyses)

In this section an exception in the Early Warning System (EWS) has to be created
based on the planned costs in the new planning plant.

Following you find an example :

Create an exception
For example, total planned costs in maintenance plant HL## exceed 1,000,000
Euros
> Logistics-PIant maintenance-Information system
Early warning system-Exception-Create
> Enter number and description
> Info structure, for example S061 or S115
> Select characteristics, for example, Maintenance plant
> Characteristic values > for example, HL##
> Requirements button > Select indicator, for example, Total planned costs
> Define Requirement button > Threshold value analysis
> Enter requirement; then set currency (Euro)
> Follow-up processing button > Area – Standard analysis > Color in list >
Set to 3 (red); Area – Periodic analyses > Activate for periodic analyses;
Send mail > Enter R/3 user > Save exception
Create a periodic analysis
Early warning system-Periodic analysis-Analysis area-Create
> Determined by the system
> Create variant (with maintenance plant HL##)
Schedule an exception in periodic analysis
Early warning system-Periodic analysis-Schedule
Set date/time and periodic values (for example, execution hourly)
Create an order and enter a completion confirmation, which fulfils the
exception criterion (planned costs > 1,000,000)
Show the mail after an hour.

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