Plant Maintenance in SAP A Functional Perspective: by - Gopinath

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

SD FI
Sales
Sales & Financial
Distribution Accounting
CO
MM Controlling
Materials
Materials
PP Mgmt AM
Production Asset Mgmt
R/3
Mgmt
Planning
Planning
QM
Quality
Client / Server Project
PS
Mgmt
PM ABAP WF
System
Plant
Plant Main-
Workflow
tenance
HR IS
Human Industry
Resources Solutions
Support & Services
System-Wide Concepts
 SAP AG
2
Plant Maintenance - Overview
SAP R/3 Modules
SD FI
Logistics Sales &
Financial Accounting
Accounting
Distrib.
Distrib.
MM CO
Material
Manag. Controlling
Manag.
PP TR
Production
R/3
Treasury
Planning
QM
Quality
Client / Server PS
Project
Manag.
Manag.
PM ABAP WF
System
Plant Workflow
Maint.
Maint.
HR IS
Human Industry
Resources. Solutions
Human Resources Cross Application

Functions R
 SAP AG
3
SD FI
MM CO
What Is Integration? PP
QA R/3
AM
PS
PM WF
HR 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
4
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 plant-
based (decentralized) or cross-plant
(centralized).
 SAP AG 1999
5
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
Concept of Plant Maintenance
Master data
Characteristics Cost records Bills of material

Classes Cost center
Task lists
Maintenance
Equipment / work centers
functional locations Maintenance
strategies
Planning
Maintenance Maintenance
notification plans
Order processing Maintenance

order
Material Purchase
reservation Capacity requisition
load
Purchase orders / Goods receipt /
Material
Time release order invoice receipt
issues
confirmation
 SAP AG 1999
7
Organizational Structures in Plant Maintenance
General Organizational Units in Logistics
Client
Company code
Plant
Location-Based Organizational Units
Maintenance plant
For example, site,
Location building, coordinate
Plant section For example, production

area, plant engineer
Planning-Based Organizational Units

Maintenance
planning plant Maintenance For example, foreman,
planner groups work scheduling
Maintenance
For example, mechanics
work centers
 SAP AG 1999
8
Cross-Plant Maintenance
Plant 1200 Plant 1300
Maintenance Maintenance
requirement requirement
Workshops
Warehouse
Plant 1000
Planning of
Maintenance
maintenance
requirement
requirements
Workshops
Material
 SAP AG 1999
9
Maintenance Work Centers
Maintenance work centers
For example:
Welding
Metalworking
Mechanics
 SAP AG 1999
10
Work Center: Contents
Basic data
General data
Capacity data
Capacity categories Capacity / pool capacity
Scheduling 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
Work Center: Main Functions
Work
Work Center
Center
11
10
Default
Default values
values Scheduling
Scheduling
for
for task
task lists
lists Costing
Costing data
data and
and
and
and orders
orders data
data available
available capacity
capacity
Lead
Lead time
time
Task
Task list
list // order
order Costing
Costing 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
12
Functional Location
Functional location = multi-level, hierarchical structure,

organized according to ...
Spatial
Technical
Functional
Criteria
 SAP AG 1999
13
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
Automatic Assignment Upon Creation
C1
Clarification
Existing plant
functional C1-M C1-B
Mechanical Biological
locations cleaning cleaning
C1-M01 C1-M02 C1-B01 C1-B02

Sand Oil/fat Pump Filtering
trap trap plant station
New
C1-M01-2
C1-M01-2 C1-M02-2 C1-B01-1 C1-B02-2
functional Ventilator Ventilator Pump 1 Filter cell
Ventilator
locations
 SAP AG 1999
15
Example of Functional Location Structure
C1
Clarification
plant
C1-M C1-B
Mechanical Biological
cleaning cleaning
C1-M01 C1-M02 C1-B01 C1-B02

Sand Oil/fat Pump Filtering
trap trap plant station
C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3 C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2
Sand Fat Filter
Reservoir Ventilator dredger Reservoir Ventilator dredger Pump 1 Pump 2 Ventilator cell
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 C1-B02-2C/1 C1-B02-2C/2

Valve 1 Valve 2 Valve 1 Valve 2
 SAP AG 1999
16
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
Equipment Master Record
Location A
Equipment
Equipment master
master record
record Equipment usage
Location B
List
Classification X
X
X
X
X
X
General
General Documents /
technical drawings
Location
Location
Multilingual texts
Organization
Organization Address / partner
Measuring points / 0471

Structure counters 0123
Permits
Internal note
 SAP AG 1999
18
Bills of Material in Company
Production
bill of material Engineering/design
bill of material
Maintenance
bill of material
Costing
 SAP AG 1999
bill of material
19
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
20
Business Process: Breakdown Maintenance
1 Notification • Technical object • Date

• Description • Malfunction
2 1 Planning • Work to be performed • Material

• Internal/external resources • Tools
3 Scheduling • Order release • Capacity leveling

• Printout • Availability check
4 2 Execution
Execution
• Planned/unplanned material withdrawal
• External procurement
5 3 Completion
• 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
21
Maintenance Order: Putting in Process
Status
'RELEASED'
Order papers
Put in process
 SAP AG 1999
22
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
23
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
Cycle for Corrective Maintenance
1 • Technical object • Date

Notification • Description • Malfunction
2 • Work to be performed • Material

Planning • Internal/external resources • Tools

4 Execution • Planned/unplanned material withdrawal

5 Completion • Time confirmation • Order settlement

History
Material usage, orders, notifications, PMIS, usage list
 SAP AG 1999
25
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
Maintenance Notification: Structure
Date / time / reported by

Notification Description
Object: Functional location
Equipment
Assembly
Material serial number
Location data
Breakdown / availability
Damage location
Notification
Text Damage
items
Cause of damage
Activity
Activities
Execution factors
Dates
Tasks
Task description
 SAP AG 1999
27
Maintenance Notification: Object Information
Orders
Maintenance dates Notifications
i
Processing days
Documents
Object information
Links Structure list
Breakdowns
 SAP AG 1999
28
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
Print Maintenance Notifications
Maintenance
Fax transfer
notification
Notification
overview Activity
report
Breakdown
report
 SAP AG 1999
30





History
 SAP AG 1999
31
Creation of Maintenance Orders
Direct creation
Maintenance order / notification
of order
Creation of order Maintenance Maintenance

based on notification notification order
Maintenance
notification
Combination of Maintenance Maintenance
maintenance notifications notification order
for maintenance order Maintenance
notification
Entry of order with Maintenance Maintenance

subsequent activity report order notification
Automatic generation of Maintenance Maintenance

maintenance order item order
from maintenance item
 SAP AG 1999
32
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
Stock Material - Process Flow
Component
assignment
Material
reservation
Order
Availability
release
check May
Printing
Automatic
availability
check May
Goods
issue
 SAP AG 1999
34





History
 SAP AG 1999
35
Resource Planning: Availability Check
Plant Material withdrawal

stock for cost center
Stock transfer
to other plant
Inward stock
movement
from purchase
order
Inward stock movement
from internal production
Stock
profile
Maximum
ATP quantity
Safety
stock
Today Requirement date
 SAP AG 1999
36
Maintenance Order: Printing
Maintenance
Fax transfer
order
Job ticket
Material
withdrawal
Operation
slip
control ticket
Confirmation
Pick list
slip
Time ticket
Object list
 SAP AG 1999
37
Order Completion Confirmation: Times / Activities
Times
Individual entry
Collective entry
Time sheet (CATS)
Activities
Activity reports
Confirmation texts
Object changes
Measurement readings
 SAP AG 1999
38
•Questions ??
•Contact Details :
mail id : gthangavelu@darylflood.com
Cell : 469-879-4674
Residence : 972-444-8510
39

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breaking through barriers to progress

Plant Maintenance in SAP

an award winning '2004 Future 50 Company'

Overview: R/3 Overview and Integration

Getting Started R/3 Applications

Support & Services

SAP R/3 Modules

Human Resources Cross Application

Common organizational structures throughout

Organization of Plant Maintenance:

Plant Maintenance is an integral part

Structure of Plant Maintenance

EQM Technical Data

PRM Preventive Maintenance

WOC Maintenance Processing

PMIS Plant Maintenance Information System

CRP Work Centers and Capacity

Concept of Plant Maintenance

Characteristics Cost records Bills of material

Order processing Maintenance

Organizational Structures in Plant Maintenance

General Organizational Units in Logistics

Location-Based Organizational Units

Plant section For example, production

Planning-Based Organizational Units

Plant 1200 Plant 1300

Maintenance Work Centers

Maintenance work centers

Work Center: Contents

Links Activity types

Work Center: Main Functions

Functional location = multi-level, hierarchical structure,

Criteria for Functional Locations

When is a functional location created?

Execution of maintenance tasks

Automatic Assignment Upon Creation

C1-M01 C1-M02 C1-B01 C1-B02

Example of Functional Location Structure

C1-M01 C1-M02 C1-B01 C1-B02

C1-B02-1A C1-B02-1B C1-B02-2A C1-B02-2B C1-B02-2C

C1-B02-2A/1 C1-B02-2A/2 C1-B02-2C/1 C1-B02-2C/2

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

Equipment Master Record

Measuring points / 0471

Bills of Material in Company

Breakdown Maintenance: Business Scenario

For breakdown maintenance, the

Business Process: Breakdown Maintenance

1 Notification • Technical object • Date

2 1 Planning • Work to be performed • Material

3 Scheduling • Order release • Capacity leveling

Maintenance Order: Putting in Process

Initial screen Individual entry

Scope Partial confirmation

Maintenance Order: Technical Completion

Status 'Technically completed'

Define location and account assignment data