SAP Plant Maintenance

Plant Maintenance - Over View

What is Integration

✓
✓
Common Organization 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
 Plant Maintenance - Over View

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 (decentralised) or cross plant (centralised).
Plant Maintenance - Over View
Benefits

✓Increase Productivity
✓Safe Environment for People in Plant
✓Reduce Machine Downtime
✓Longivity of Machines
Plant Maintenance - Over View

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
Master Data in SAP Plant Maintenance

Functional Functiona
Location l
Location

Work Work Equipment Equipment

Center Centre
s
SAP PM SAP PM:
Master Master
Data Data

Characterstics / Task Bills of

Class List material

Measuring Measurin
Point / g
Point/
Counter Counters
Plant Maintenance - Resource Tools

PM Resource Tools
Structure Indicator Coding Templet

X = Alphanumerical
Character

A = Alphabetic
Character

N = Numeric
Character

✓ Structure indicator include coding template and hierarchy level,

by using alphanumerical characters but not special characters are
allowed
✓ which character is to be used and how these charaters are
grouped and split is controlled in the coding templet
✓ The hierarchy levels are used to define the levels in structure.
Structured Functional Location

❖ Functional Location created according hierarcy, & can be structured on

one of the following basis

✓ Functional (e.g: a Power station, a Lathe area)

✓ Process related (e.g: Colour, Assembly)
✓ Spatial (e.g: Location)
 Equipment - Overview

✓An Equipment represents a physical object which can be independently maintained in

the industry.
✓Equipment is an asset that can be moved from one place to another.
✓SAP equipment master record contains the details regarding actual industry objects
as required from the plant maintenance perspective.

Equipment is created in SAP system for the following reasons:

✓Monitoring of the objects that require maintenance during their usage.
✓Carry out maintenance tasks for the individual objects from time to time.
✓Keep a record of the maintenance tasks performed for the objects for future reference.
✓Analysis of objects performance over a period of time.
 BOM (Bill of Materials)

✓BOM bills of material can be defined as lists of components

✓BOM which links to equipment. Since equipment is unique, equipment BOM is also
unique.
✓These lists contain material numbers of components, their quantities and units of
measure (UOM).
✓The components of SAP PM bills of material can be either of stock (S) or non-stock (N)
materials.
✓The primary usage of maintenance BOM is to describe the structure of a maintenance
object.
✓Using BOM enables us to specify the exact location(s) where maintenance tasks are to
be performed.
Maintenance Work Center

Functional
Location

Mechanic Carpenter

Cleaner

Maison Maintenance wok

center

Fitter Welder
Processing of Maintenance Task

Unit 2
Workflow Supported Maintenance Processing for
Unplanned Maintenance Tasks
Planning Maintenance Task
✓Direct creation of a maintenance order

✓Creation of a maintenance notification with immediate order

✓Creation of a maintenance order based on a notification

✓Combination of maintenance notification to make an order

Difference Between Notification & Order
❖Maintenance Notifications are Reporting objects to record:
✓Maintenance requirement
✓Cause, Object Impacted, Tasks due & Activities Performed
❖Types:
✓Maintenance Request. Malfunction (Breakdown) Report,
✓Activity Report, Service Notifications
✓Maintenance Notifications generally do not record Costs
❖Maintenance Orders are a complete record of:
✓Operations performed
✓Components used (Stock/Non stock)
✓External Services
✓Time, plan costs and actual costs posted
✓Settlements executed
❖Types:
✓Breakdown Orders, Corrective Orders, Predictive Orders,
✓Refurbishment Orders, Preventive Orders
Business Process of PM
Breakdown Maintenance Processing
Malfunction Reports Malfunction
Order

Technical object Date Maintenance

Notification
Description Malfunction
Planner

Scheduling Order release Capacity leveling

Printout Availability check

Technician /
Execution Planned/unplanned mat. withdrawal
Storeperson

Time conf. Order settlement

Completion Maintenance
Tech. completion Technical confirmation Supervisor

History Material usage, Orders, Notification, PMS, Usage List

Corrective Maintenance Processing
Internal External Service Material

Technical object Date Maintenance

Notification
Description Malfunction
Planner

Planning Work to be performed Materials

Internal/External Resources Tools

Scheduling Order release Capacity leveling

Printout Availability check

Execution Technician /
Planned/unplanned mat. withdrawal Storeperson

Time conf. Order settlement Maintenance

Completion Supervisor
Tech. completion Technical confirmation
Plant Maintenance - Overview

Stock Material Process

Flow (Reservation)
Stock Material Process Flow(Reservation)

Create
Notification
(IW21)
Order Release
(IW32)
Order Planning,
Create Order refer Assign operation,
from Notification CTRL Key PM01,
(IW22) Input Stock Material Goods Issue
(IW32) Material
(MIGO)

Order
Order Order Order Technical Confirmation for
Order Closure Settlement Completion Actual Work
Closure
(CO99) (KO88) (IW32) (IW41)
(CO99)
Plant Maintenance - Overview

Non Stock Material Process

Flow (Reservation)
Non Stock Material Process Flow
Order Planning, Assign
Create Notification Create Order refer Order Planning,
Operation,CTRL Assign
KeyPM01
from Notification operation, CTRL Key Order Release
(IW21) Non-Stock Material
PM01,
(IW22) (IW32)
Non-Stock
(IW32) Material
(IW32)

Release Purchase Create PO refer from Release PO Goods Receipt

Requisition Purchase Requisition from PO
(ME54N) (ME21N)
(ME29N) (MIGO)

Usage
Decision/Quality Order Confirmation Order Technical Settlement a
Inspection for Actual Work Completion (IW32) maintenance order
(QA32) (IW41) Sys. Status - TECO (KO88)

Order Closure
(co99)
Order
Closure
(co99)
Func, Loc, Equipment & Bom Structure List
Notification Transaction
Maintenance Order Transaction
Report List of Order