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SAP PM Module Training

SAP R/3

PLANT MAINTENANCE SYSTEM

2 Presentation Title | Confidential | Document ID | Apr 17, 2017

PLANT MAINTENANCE SYSTEM

I. MANAGING MASTERS
II. MANAGING MAINTENANCE PROCESSES
III. MANAGING REPORTS

3 Presentation Title | Confidential | Document ID | Apr 17, 2017

I. MANAGING MASTERS 4 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

Maintenance Plan 5 Presentation Title | Confidential | Document ID | Apr 17. Work Center • Cost Center /Internal Order • Category 6. Equipment Master • Main Planner Group 3. MIC’s • Main Work Center 5. Functional Locations • Plant 2. Maintenance Item • UOM 9. Task List Master • Strategy 8. Measuring Point • Company Code 7. MAINTENANCE MASTERS BASIC MASTERS CONTENTS OF MAINTENANCE OF MASTERS 1. 2017 . Class & characteristics • Plant Section 4.

Class & characteristics 4. Task List Master 8. MIC’s • Function Location Category 5. Functional Locations • Function Location 2. Maintenance Item 9. MAINTENANCE MASTERS BASIC MASTERS CONTENTS OF MAINTENANCE OF MASTERS 1. 2017 . Work Center • Plant 6. Equipment Master Structure 3. Measuring Point 7. Maintenance Plan 6 Presentation Title | Confidential | Document ID | Apr 17.

or any other Special criteria.  Each functional location is managed independently in the system. Gives information about how the Technical System is sub divided into Individual Functional Units. so that you can : • Manage individual data from a maintenance perspective for the object • Perform individual maintenance tasks for the object • Keep a record of the maintenance tasks performed for the object • Collect and evaluate data over a long period of time for the object 7 Presentation Title | Confidential | Document ID | Apr 17. FUNCTIONAL LOCATION STRUCTURE Functional locations Structure is a hierarchical Presentation of a Tech. System. Functions. Individual function Units are defined on the Basis of Process Orientation. 2017 .

FUNCTION LOCATION STRUCTURE Description Code Structure Indicator GIL Structure Indicator Text GIL Cement Division Edit Mask AAA-AANN-AAX-AAX-XXX-XXXXX Hierarchy Levels 1 2 3 4 5 6 Example Hierarchy Edit Mask Code Description Level Level 1 AAA GIL Grasim Industries Limited Level 2 AANN RC01 Raja shree Cement Level 3 AAX RC1 Raja shree Cement Unit-I Level 4 AAX CM1 RC1 Cement Mill-1 Level 5 XXX FEG RC1 Cement Mill -1 Feeding Group Level 6 XXXX 8 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

2017 . MAINTENANCE MASTERS BASIC MASTERS CONTENTS OF FUNCTIONAL LOCATION MASTER 1. Task List Master 8. Maintenance Plan 9 Presentation Title | Confidential | Document ID | Apr 17. MIC’s • Plant 5. Maintenance Item 9. Work Center 6. Class & characteristics 4. Equipment Master • Function Location Category 3. Functional Locations • Function Location Structure 2. Measuring Point 7.

FUNCTION LOCATION CATEGORY Category Description C Colony Functional Locations G General Functional Locations H Hierarchical M Plant & Machinery F Locations N Mines Functional Locations O Office Functional Locations T Power Generation F. Locations U Utility Functional Locations 10 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

2017 . NAVIGATE > SAP SCREEN  Display of Function Location-[IL03]  List Editing of Function Location-[IH06]  Display ( Multi Level) Function Location[IL07] DISPLAY CONTENTS:  Display Action Log  Object Information 11 Presentation Title | Confidential | Document ID | Apr 17.

MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF MAINTENANCE OF EQPT MASTER 1. Maintenance Item  Class 9. Equipment Master  Plant 3. Object Type 5. Measuring Point  Main Work Center 7. Maintenance Plan  Warranty data 12 Presentation Title | Confidential | Document ID | Apr 17. Functional Locations  Equipment Category 2. Work Center  Plant Section 6. 2017 . Class & characteristics  Functional Location  Main Planner Group 4. MIC’s  Tech. Task List Master  Cost Center /Internal Order  Company Code 8.

Electrical Equipment.. EQUIPMENT CATEGORY Defining Equipment Categories is a facility in SAP/PM to group the vast variety of Equipments that any manufacturing Organization can have in their Plant. In GIL. 2017 . One of the methods of grouping similar Equipments is to differentiate them on the basis of their Use and / or the Function that they perform e. this is the basis of defining Equipment Category shown in the next two slides 13 Presentation Title | Confidential | Document ID | Apr 17.g.

EQUIPMENT CATEGORY CATEGO EQUIPMENT EXAMPLES RY A AUTOMOBILE CARS/JEEP/MOBILE VAN C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS D DUMMY EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR TRANSFER. 2017 . NOT TO BE USED E ELECTRICAL EQUIPMENTS MOTORS/TRANSFORMERS/SWITCH GEARS I INSTRUMENT EQUIPMENTS RTD’S/PROXIMITY SWITCHES/FIELD INSTRUMENTS/PANELS M MECHANICAL EQUIPMENTS GEAR BOXES/DPC/DBC/BELT CONVEYORS N MINES EQUIPMENTS SHOVELS/DUMPERS/DRILLING MACHINES 14 Presentation Title | Confidential | Document ID | Apr 17.

2017 . EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY. EQUIPMENT CATEGORY CATEGOR EQUIPMENT EXAMPLES Y P PROCESS EQUIPMENTS CYCLONES/HOPPERS Q QC TEST EQUIPMENTS CUBE TESTING MACHINE / COMPRESSIVE STR MACHINE R PRODUCTION RESOURCES/TOOLS CRANES T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER U UTILITY EQUIPMENTS COMPRESSOR/WATER PUMPS NOTE: ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO TPP MECH/TPP ELEC CATEGORY. 15 Presentation Title | Confidential | Document ID | Apr 17.

2017 . 80000000 89999999 S Safety Equipments 90000000 99999999 Q QC Test Equipments 1000000 1999999 16 Presentation Title | Confidential | Document ID | Apr 17. EQUIPMENTS CATEGORY & NUMBER RANGE Number Number range Category Description Range From To M Mechanical Equipments 10000000 19999999 E Electrical Equipments 20000000 29999999 I Instrumentation Equipments 30000000 39999999 P Process Equipments 40000000 49999999 T TPP & DG Equipments 50000000 59999999 N Mines Equipments 60000000 69999999 Automobiles Equipments A 70000000 79999999 C Civil Objects & General Equipt.

Examples : ME_GEARBOX Gear Box EL_MOTORS Electrical Motors ME_FANS Fans 17 Presentation Title | Confidential | Document ID | Apr 17. TECHNICAL OBJECT TYPE Technical Object Types are the logical grouping of Objects on the basis of similarity of function being performed by each one. 2017 .

Different Planning Plants in GIL are : Aditya Cement Grasim Cement Vikram Cement Rajashree Cement Grasim South Birla Super Cement (Hotgi) Birla Plus Cement (Bhatinda) 18 Presentation Title | Confidential | Document ID | Apr 17. Planning Plant is also a Maintenance Plant. In GIL . 2017 . PLANNING PLANT Plant in which maintenance tasks are planned and executed.

MAIN WORK CENTER Main Work Center is Logical Grouping of all Work Centers. • Civil Department.G. • Instrumentation Department. • Process Department. Different Main Work Centers defined are : • Mechanical Department • Electrical Department. who are executing Mechanical Maintenance activities . Mechanical Main Work Center is a Group of Plant Maintenance Persons. E. 19 Presentation Title | Confidential | Document ID | Apr 17. which are Performing similar nature of Maintenance Tasks/Activities in different Plant Sections. 2017 . Etc.

Plant Category Description GC01 RM1 Raw Mill -1 GC01 CO1 Coal Mill -1 GC01 KL1 Kiln -1 GC01 CM1 Cement Mill -1 GC01 PP1 Packing Plant -1 20 Presentation Title | Confidential | Document ID | Apr 17. 2017 . PLANT SECTION Plant Section is a division of Maintenance Plants into Production Areas.

PLANNER GROUP CODIFICATION LOGIC PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION MCM = Mechanical + Cement Mill ECM = Electrical + Cement Mill ICM = Instrumentation + Cement Mill 21 Presentation Title | Confidential | Document ID | Apr 17. 2017 . PLANNER GROUP Planner Group defines the Group of People (Employees) responsible for Planning and Execution of Maintenance Activities in a Particular Plant.

Internal Order will be used in Mines Equipment only. COST CENTER/ INTERNAL ORDERS Cost Centers are logical Organizational Units where the costs are incurred for value addition . Cost Center Concept as applied in GIL : Plant Section = Superior Cost Center Department = Sub Cost Center in that Plant section CEMENT MILL Mechanical Electrical Instrumentation Process 22 Presentation Title | Confidential | Document ID | Apr 17. Internal order is nothing but an intermediate cost collector between PM order and cost center. 2017 . Costs incurred are ultimately settled to Cost Centers through Orders.

 NAVIGATE > SAP SCREEN  Creation of Equipment-[IE01]  Change of Equipment-[IE02]  Display of Equipment-[IE03]  List Editing of Equipment-[IH08]  Display ( Multi Level)-[IE07] DISPLAY CONTENTS:  Display of Usage List  Display Action Log  Display Object Information  Installation & Dismantle 23 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

Equipment Master  Class Group 3. Measuring Point 7. MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF CLASS & CHARACTERISTICS MASTERS 1. Work Center Characteristics Master 6. Class & characteristics  Characteristics Group 4. Maintenance Plan 24 Presentation Title | Confidential | Document ID | Apr 17. Functional Locations  Class Type 2. Maintenance Item 9. Task List Master 8. MIC’s  Unit of Measure for 5. 2017 .

for planned Maintenance & obtaining the History of that Class of Equipments. CLASS  Classes are :  Logical Grouping of Equipments having Similar Functions.  This information can be used for Proper Planning of Spares.  Class data will never Change throughout the entire Productive Life-Cycle of the Equipment. 25 Presentation Title | Confidential | Document ID | Apr 17. 2017 .  Class Mainly Depends on the Main Function / Activity being Performed by that Equipment.  It helps to know the Number of Equipments having the same Class.

CHARACTERISTICS  Characteristics are the Specifications or Designed Parameters of Measurement for the Equipments. Gear Ratio of Gear Box. 2017 . Flow of Fan . Ex. For Example:  Select Gearbox of Particular Make / Ratio. Enter Relevant Values of these Characteristics.  Select Class as Gearbox & Characteristics as Make/ Ratio.  Combination of Class and Characteristics helps in Precise search of Equipments.  System will search & display all Gearboxes satisfying above Characteristics Values 26 Presentation Title | Confidential | Document ID | Apr 17.

CLASS Mechanical Electrical Class Description Class Description GEARBOX GEARBOX LTMOTOR LT MOTOR BUCKETELELVATOR BUCKET ELELVATOR LTFEEDER LT FEEDER BALLMILL BALL MILL BATTERY BATTERY BAGHOUSE BAG HOUSE BREAKER BREAKER 27 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

Equipments Specs. Class Group PM_EQ_INST PM Inst.Char. Char Group PM_EQ_TPDG PM TPP & DG Equip. Group PM_EQ_MINE PM Mine. Char. CLASS AND CHARACTERISTICS GROUPS CODES Char.Char. Equipments Specs. Specs. 2017 . Specs.Char. Specs. Group Code Description PM_EQ_ELEC PM Elec. Group PM_EQ_MECH PM Mech. Group PM_EQ_GENL PM General Equip. Equipments Specs.Char. Equipments Specs.Char. Group PM_EQ_PROC PM Proc. Equipments Specs. Group 28 Presentation Title | Confidential | Document ID | Apr 17. Group PM_EQ_SAFE PM Safety Equip.

[CL30N ] 29 Presentation Title | Confidential | Document ID | Apr 17. 2017 . NAVIGATE > SAP SCREEN  Display of Class List [CL03]  Find Object in Class.

Maintenance Plan 30 Presentation Title | Confidential | Document ID | Apr 17. MIC’s 5. Functional Locations 2. Work Center 6. MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF MIC’s MASTER  Plant 1. Task List Master 8. Class & characteristics 4. Equipment Master  Range of Characteristics Value 3. Maintenance Item 9. Measuring Point 7. 2017 .

Example: Mili-amperes / Mili-volts for weigh Feeder 31 Presentation Title | Confidential | Document ID | Apr 17. 2017 . MASTER INSPECTION CHARACTERISTCS  Specific parameters of an Equipment for Calibration  Parameters to measure whether Equipment is performing its function The Parameter driving / governing Equipment performance/Output is within acceptable limits.

 NAVIGATE > SAP SCREEN  Find out The Maintenance Inspection Characteristics prepared-[QS24] 32 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

Measuring Point  Work Unit 7. MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF WORK CENTER MASTER 1. Equipment Master  Work Center Category 3. 2017 . Task List Master 8.Time 6. Maintenance Item 9. Functional Locations  Plant 2. Class & characteristics  Control Key 4. Maintenance Plan 33 Presentation Title | Confidential | Document ID | Apr 17. MIC’s  Cost Center 5. Work Center  Work Dimension .

Codification Logic : M1F1W3K = Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi MC1F1W3K = Mech. Category Description 0021 Mechanical Permanent 0022 Mechanical Contractor Example : M1F1W3K. WORK CENTER Work Center is a Person/Group of Persons. MC1F1W3K etc. Contractor / 1 Fitter /1Welder / 3 Khalasi 34 Presentation Title | Confidential | Document ID | Apr 17. Work Center Category Each Department will have two categories. 2017 . who perform Maintenance Activities. Permanent and Contractor.

2017 . NAVIGATE > SAP SCREEN Work Center List-[IR03] DISPLAY CONTENTS:  Relevant Number for Permanent and Contractor Work centers for your department. 35 Presentation Title | Confidential | Document ID | Apr 17.  Different combinations of Skills.

Functional Locations  Equipment Master 2. MIC’s  Characteristics 5. 2017 . Work Center  Unit of Measures 6. Equipment Master  Function Location Master 3. MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF MEASURING POINT MASTER 1. Maintenance Item 9. Measuring Point 7. Task List Master 8. Maintenance Plan 36 Presentation Title | Confidential | Document ID | Apr 17. Class & characteristics  Category of Measuring Point 4.

 Measurement readings are taken for an Equipment at regular interval to know the Condition at that time. MEASURING POINT  It is a Measurement characteristic/Parameter attached to an Equipment  Describe the Physical and/or Logical Locations of Equipment at which a Condition / Parameter is to be measured.  Measuring Point will be always for an Equipment or FL or assembly but Generally for Equipments. 2017 . 37 Presentation Title | Confidential | Document ID | Apr 17.

Example: Running hours of Any Equipment Lubrication Consumption. 2017 . 38 Presentation Title | Confidential | Document ID | Apr 17. Measuring Point is also Used as Counter where values Measured by a Measuring Point can be summed up during a time period for monitoring and control . MEASURING POINT Continued..

2017 . NAVIGATE > SAP SCREEN(MP)  Creation Of Measuring point [IK01 ]  Change / Display Of Measuring Point [IK02/ IK03]  Display List Editing-[IK07]  Create Entry List-[IK31] Collective entry of measuring document-[IK34] DISPLAY CONTENTS: Transfer of Measuring point 39 Presentation Title | Confidential | Document ID | Apr 17.

MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF TASK LIST MASTERS 1. Function Locations  Group Coding 2. 2017 . Maintenance Plan 40 Presentation Title | Confidential | Document ID | Apr 17. Measuring Point  Set of Operations 7. MIC’s  Maintenance Strategy 5. Task List Master  MIÇ’s 8. Class & characteristics  Planning Plant 4. Maintenance Item 9. Equipment Master  Counter 3. Work Center  Work Center 6.

Three types of Task Lists :  Functional Location Task List[T]  Equipment Task List[E]  General Task List[A] 41 Presentation Title | Confidential | Document ID | Apr 17. 2017 . TASK LIST A Set of Activities to be Performed on an Equipment or Functional Location.

SD = Shutdown . M = Mechanical. T = TPP. Q = QC. Radial.S = Safety 3 XX Equipment Short "Equipment Class Code": GB = Gear Box. AT = Analyzer. GS = GS01. AM = AMC Tasks. GC = GC01. etc 4 X Equipment Class Code Type( application) : GB Gear Box Helical. IN = Inspection (attribute/Value EN-Environment. CA= Calibration . BS = BS01. P = Process. BF= Bag Filter. GS = GS01. 2 X Discipline: E = Electrical. MO= DC Motor. BE-Bucket Elevator Belt/ Chain 5 XX Type of Maintenance Task List: PM=Preventive Maintenance . N = Mines. 2017 . BC = Belt Conveyor.) J-Jishu Hozen ( General Inspection ) ZX- Safety Example: GCMGBHPM GCM-GBH-PM 1M Checks GCEMODPM GCE-Motor-DC-PM 3M Checks 42 Presentation Title | Confidential | Document ID | Apr 17. TASK LIST CODIFICATION seq Codification Logic for defining Task List Group .It has to be Planning Plant / Maintenance Specific 1 XX GIL Plant Short Code: RC = RC01. I =Instrumentation.

These Maintenance Strategies can be selected By User to carry out Maintenance Activities depending Upon :--  Age of Equipment  Design of Equipment  Importance of Equipment in Production Process  Maintenance Practices of Organization. MAINTENANCE STRATEGY Set of Predefined Prefixed Time Intervals ( Called Packages) grouped at Which Preventive Maintenance Activities can be taken Up. 43 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

 GILDAY -.Frequencies Specified in “ PERFHR” Are150HR / 250HR / 500HR/ 1000H 44 Presentation Title | Confidential | Document ID | Apr 17. 2017 .Frequencies Specified in “ GILMON” Are 6M/ 1Y/ 2Y/ 5Y  MINEHR -. MAINTENANCE STRATEGIES Continued..Frequencies Specified in “ MINEHR” Are 100HR/ 300HR / 350HR/ 400HR  PERFHR -.Frequencies Specified in “ GILDAY” Are 1W / 2W / 1M / 3M / 6M / 1Y  GILMON-.

45 Presentation Title | Confidential | Document ID | Apr 17.  GILMON: Strategy is Used for Frequencies of Checks More than 6M.  MINEHR: Strategy is Used For MINES Preventive Maintenance Planning..  GILDAY: Strategy is Used for Frequencies of Check Up to 6M.APPLICATION: Continued.  PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance Planning. 2017 .

MAINTENANCE PACKAGE Strategy GILDAY Cycle Length UOM Maintenance Cycle Text Cycle Short Text 7 DAY Weekly (1 Week ) 1W 14 DAY Fortnightly (2 Weeks ) 2W 28 DAY Monthly ( 4 Weeks ) 1M 84 DAY Quarterly ( 12 Weeks ) 3M 168 DAY Half yearly ( 24 Weeks ) 6M 336 DAY Yearly ( 48 Weeks ) 1Y Strategy GILMON Cycle Length UOM Maintenance Cycle Text Cycle Short Text 6 MON Half yearly 6M 12 MON Yearly 1Y 24 MON 2 Yearly 2Y 48 MON 5 Yearly 5Y 46 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

2017 .. Strategy MINEHR Cycle Length UOM Maintenance Cycle Text Cycle Short Text 96 HR 100 Running Hours ( 96 Hrs) P1 312 HR 300 Running Hours ( 312 Hrs) P2 360 HR 350 Running Hours ( 360 Hrs) P3 408 HR 400 Running Hours ( 408 Hrs) P4 504 HR 500 Running Hours ( 504Hrs) P5 1008 HR 1000 Running Hours (1008 Hrs) P6 1512 HR 1500 Running Hours (1512 Hrs) P7 2016 HR 2000 Running Hours (2016 Hrs) P8 2496 HR 2500 Running Hours ( 2496 Hrs) P9 3000 HR 3000 Running Hours ( 3000 Hrs) 1P 47 Presentation Title | Confidential | Document ID | Apr 17. MAINTENANCE PACKAGE Continued.

2017 .) P1 240 HR 250 Running Hours ( 240 Hrs.) P2 504 HR 500 Running Hours ( 504 Hrs.) P3 1008 HR 1000 Running Hours (1008 Hrs) P4 2496 HR 2500 Running Hours (2500 Hrs) P5 4032 HR 4000 Running Hours (4032 Hrs) P6 8064 HR 8000 Running Hours (8064 Hrs) P7 12096 HR 12000 Running Hours (12096 H) P8 16128 HR 16000 Running Hours ( 16128 H P9 24192 HR 24000 Running Hours ( 24192 H 1P 32256 HR 32000 Running Hours ( 32256 H 2P 48 Presentation Title | Confidential | Document ID | Apr 17. Strategy PERFHR Cycle Length UOM Maintenance Cycle Text Cycle Short Text 144 HR 150 Running Hours ( 144 Hrs.. MAINTENANCE PACKAGE Continued.

 NAVIGATE > SAP SCREEN  Display Task List-[IA07]  List Editing Task List-[IA09] DISPLAY CONTENT:  Find Task Lists in your Planner group. 2017 . 49 Presentation Title | Confidential | Document ID | Apr 17.

2017 . Measuring Point 7. Maintenance Plan 50 Presentation Title | Confidential | Document ID | Apr 17. Maintenance Item 9. Work Center 6. MIC’s  Strategy 5. Equipment Master Master 3. Class & characteristics  Task list Master 4. MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF MAINTENANCE ITEM MASTER 1. Task List Master 8. Functional Locations  Equipment /Function Location 2.

2017 . MAINTENANCE ITEM Maintenance Item describe Preventive Maintenance Tasks to be performed on an Equipment at Predefined Interval Maintenance Item = Equipment + Task List with set of operations with Maintenance Package 51 Presentation Title | Confidential | Document ID | Apr 17.

Maintenance Plan 52 Presentation Title | Confidential | Document ID | Apr 17. Task List Master 8. Class & characteristics  Scheduling parameter 4. Maintenance Item 9. MIC’s 5. Work Center 6. Functional Locations  Maintenance Item Master 2. MAINTENANCE MASTERS BASIC MASTERS BASIC CONTENTS OF MAINTENANCE PLAN MASTER 1. Measuring Point 7. 2017 . Equipment Master  Strategy 3.

2017 . MAINTENANCE PLAN Maintenance Plan is the Scheduling of Task List attached to an Equipment (Maintenance Item ) on Time Scale ( According to Factory Calendar ) or Performance scale ( According to Counter i. Number of Hours).e. Plan = Maintenance Item + Scheduling Parameters 53 Presentation Title | Confidential | Document ID | Apr 17.

Actual delay 54 Presentation Title | Confidential | Document ID | Apr 17. For GILMON it will be +/. MAINTENANCE SCHEDULING PARAMETER  TOLERENCE: ( 50% ) It is the difference between planned date and TECO date . If difference between planned date and TECO date is less than 50% of smallest interval (smallest package) . considering the gap between planned date and TECO date. For GILDAY .  SHIFT: 100% . as minimum frequency is 1w. it will be + / .i. If condition given in “Tolerance” is true it will shift the maintenance cycle by : given shift % x difference between planned date and TECO date .5 days .3.given in %age for deciding whether maintenance cycle should be shifted or not. either + or – side. there will be no shift.e. 2017 .3 months as min freq is 6M. Shift factor” will be effective only if difference between planned date and TECO date is more than 50% of smallest interval (smallest package) .

MAINTENANCE SCHEDULING PARAMETER
Continued..

 CALL HORIZON 50%

It indicates that an advance intimation of planned maintenance will be
given by 0.5 x minimum frequency of strategy selected through order
generation .

FOR GILDAY :

1W Being minimum frequency , you will get weekly order 3.5 days
in advance if call horizon is 50%.

55 Presentation Title | Confidential | Document ID | Apr 17, 2017

II. MANAGING MAINTENANCE PROCESSES

56 Presentation Title | Confidential | Document ID | Apr 17, 2017

MAINTENANCE PROCESSES

BASIC PROCESSES BASIC STEPS OF MAINTENANCE
PROCESSES
1. Preventive Maintenance • Creation of Notification
• Creation of Orders
2. Break down Maintenance
• Execution of Orders
3. Shut down Maintenance • Confirmation of Orders
4. Condition base Maintenance • Technical Confirmation of
5. Work shop Repair Orders
6. External Repair/Services • Creation of Purchase Request
• Creation of Purchase Orders
7. Calibration
• Service Entry Sheets
• Creation of Measuring Points
& Measuring Documents
• Installation / De-installation of
Equipments
57 Presentation Title | Confidential | Document ID | Apr 17, 2017

PREVENTIVE MAINTENANCE PROCESS BASIC PROCESSES 1. Preventive Maintenance BASIC STEPS OF PREVENTIVE MAINTENANCE PROCESS 2. External Repair/Services • Technical Completion of 7. 2017 . Break down Maintenance • Selection of Orders 3. 1. Calibration Orders 58 Presentation Title | Confidential | Document ID | Apr 17. Condition base Maintenance 5. Work shop Repair • Confirmation of Orders 6. Shut down Maintenance • Execution of Orders 4.

. PREVENTIVE MAINTENANCE PROCESS Selection of Order H/L TO ORDER TYPES BASIC STEPS OF MAINTENANCE Go to T. 1.to ……) Enter Status exclusive in CRTD. Code . Multiple Selection TECO & CLSD Enter Maintenance Plant Enter Planner group for Order Select from Drill Down Execute by clicking button Order list of relevant section Appears 59 Presentation Title | Confidential | Document ID | Apr 17.IW39 PROCESSES • Selection of Orders Flag Outstanding & In process check box • Execution of Orders Enter Order Type PM01 Select from Drill Down • Confirmation of Orders • Technical Completion of Orders Enter Period ( Date from…. CNF . 2017 .

• User will be able to compare Cost Of Preventive Maintenance vis-à-vis Breakdown and Shutdown Maintenance. • Order Numbering is blocked for this Order • User will get Preventive Maintenance Orders under Maintenance Activity Type - PVM . • User will be able to judge the effectiveness of Preventive Maintenance Plans by this Order Type. ORDER TYPES PM01 --. Annual Maintenance Contract Orders under Maintenance Activity Type - AMC and Inspection Orders under Maintenance Activity Type INW 60 Presentation Title | Confidential | Document ID | Apr 17. 2017 . • This Order type will help User to find out Cost of Preventive Maintenance exclusively for his Plant section/Planner group.PREVENTIVE MAINTENANCE ORDERS • These Orders are Planned by SAP System • User can not generate PM Work Order for this Order Type externally.

Type : WFM) • Opportunity Based Maintenance (Maintenance Activity Type: OPP) The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be booked under MAT.Fortnightly.  PM03: SHUTDOWN MAINTENANCE ORDERS This Order Type indicates • Annual Shutdowns ( Maintenance Activity Type: SDM) • Planned Weekly..Monthly Stoppages ( Maintenance Act.SDM. Material . Machine . ORDER TYPES Continued. Production loss is also associated with this type of Order . • User can further segregate the breakdowns of Equipments under Warranty / Insurance from other Breakdowns. 61 Presentation Title | Confidential | Document ID | Apr 17.  PM02: BREAKDOWN MAINTENANCE ORDERS •This Order Type is exclusively for Breakdown registration of Equipments •This Order Type indicates Unplanned stoppage in Production Process • In addition to consumption of Recourses like Men . 2017 .

ORDER TYPES Continued.CAL .Fortnightly. However .  PM05: CALIBRATION MAINTENANCE ORDERS • This Order Type is applicable for Calibration of Equipments • These Orders are Planned by System .  PM03: SHUTDOWN MAINTENANCE ORDERS • Only Planned Weekly. • This Order Type has MAT. 62 Presentation Title | Confidential | Document ID | Apr 17.  PM06 : CORRECTIVE MAINTENANCE ORDERS • The jobs covered under this Order Type are of 2 types: Corrective Actions suggested under WHY-WHY Analysis to avoid recurrence of Breakdown will be covered under Maintenance Type – WHY . if required for unplanned Calibration jobs.. 2017 .Monthly Stoppages will be booked under Maintenance Activity Type – WFM • Other Maintenance jobs not planned but undertaken because of availability of Opportunity are booked under MAT-OPP. User can also raise Order externally .

g.g. • These are of Minor nature Repair Jobs. ORDER TYPES Continued. PM06 : CORRECTIVE MAINTENANCE ORDERS • Other Maintenance Jobs of Corrective Nature e.CRM  PM07 --. Replacement of Worn Out Chain/ Worn-out Hammers etc • MID .g. E..CONDITION BASED MAINTENANCE ORDERS • This Order Type is applicable for jobs planned on the basis of Condition of Spares. Removal of Unsafe Conditions where Breakdown has not occurred will be covered under MAT. •This Order Type should not be used unless it satisfies above condition 63 Presentation Title | Confidential | Document ID | Apr 17. being Condition Monitoring Department . Leakage of Water Tap in Administration Building garden. E. will use this Order Type for advising repair / replacements on the basis of Condition E. Maintenance Requests from other departments .GENERAL MAINTENANCE ORDERS • This Order Type is applicable for UNDEFINED jobs NOT FALLING under above categories and not related to Equipment.g. Removal of Abnormalities/Defects. Hardness/Thickness/Vibrations etc  PM08 --. 2017 .

 PM11: CAPEX/BLOCK ORDERS • All Work Orders raised for Project Work are covered under this Order Type and MAT- CAP  PM12 --. 2017 . ORDER TYPES Continued.REW • Tyre Retreading jobs should be registered under MAT – RET • External Repair jobs should be registered under MAT – RVN  PM10: IMPROVEMENT/MODIFICATION ORDERS • All jobs of Improvements and Modifications in Maintenance (Reliability MTTR/MTBF/Maintainability/Availability) are covered under Maintenance Activity Type – IMO • Suggestions given by Consultants/Experts/Other Units/ Other sources like Websites. They are: • Work Shop jobs should be registered under MAT – RWS • Rewinding jobs should be registered under MAT .  PM09: REPAIR MAINTENANCE ORDERS There are Four different Activity Types or jobs covered under this category..CIVIL MAINTENANCE ORDERS • All Work Orders raised for Civil Work E. Building/ Plumbing/ Carpentry/ Painting/ Foundation 64 etc are covered Presentation under| this Title | Confidential Order Document Type ID | Apr and MAT-CIV 17. Magazines etc are covered under Maintenance Activity Type – CON. Manuals.g.

CON PM11 Capex / Block order CAP PM12 Civil Maintenance Order CIV QCAL QC Insp.INS PM03 Shutdown Maintenance Order SDM.WHY PM07 Condition Based Maintenance CBM PM08 General Maint Order GEN PM09 Repairs Order RWS.AMC.WAR.INW PM02 Breakdown Maintenance Order BDM.OPP. 2017 . MAINTENANCE ACTIVITY TYPES IN PM ORDERS Order Type Description Order Activity Type PM01 Preventive Maintenance Order PVM.REW PM10 Improvement/Modification Order IMO.RET./ Calibration Order CAL 65 Presentation Title | Confidential | Document ID | Apr 17.WFM PM05 Calibration Order CAL PM06 Corrective Maintenance Order CRM.RVN.

. CNF . Code .to ……) Enter Status exclusive in CRTD.IW39 PROCESSES • Selection of Orders Flag Outstanding & In process check box • Execution of Orders Enter Order Type PM01 Select from Drill Down • Confirmation of Orders • Technical Completion of Orders Enter Period ( Date from…. Multiple Selection TECO & CLSD Enter Maintenance Plant Enter Planner group for Order Select from Drill Down Execute by clicking button Order list of relevant section Appears 66 Presentation Title | Confidential | Document ID | Apr 17. 1. 2017 . PREVENTIVE MAINTENANCE PROCESS Selection of Order H/L TO ORDER TYPES BASIC STEPS OF MAINTENANCE Go to T.

1. 2017 . PREVENTIVE MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE PROCESSES Select desired order • Selection of Orders • Execution of Orders Move to SAP Screen • Confirmation of Orders • Technical Completion of Orders 67 Presentation Title | Confidential | Document ID | Apr 17.

PREVENTIVE MAINTENANCE PROCESS Execution of Orders BASIC STEPS OF MAINTENANCE Go to T. Item category. 1. Code .IW32 PROCESSES • Selection of Orders Enter number of Selected Order • Execution of Orders • Confirmation of Orders Order status will be Release PM01 Type Selected changed to REL from • Technical Completion of Orders Order CRTD Go to Operation TAB and Change operations etc if reqd Select operation & Go to Component TAB if Material Required Select required Component Enter reqd Qty . 2017 . Storage Location & Batch Come to Header data Tab Enter Start Date & Time 68 Presentation Title | Confidential | Document ID | Apr 17.

PREVENTIVE MAINTENANCE PROCESS Schedule Order by Clicking End date & time will BASIC STEPS OF MAINTENANCE be changed by system PROCESSES Determine cost by clicking • Selection of Orders • Execution of Orders Save the Order • Confirmation of Orders • Technical Completion of Orders Move to SAP Screen 69 Presentation Title | Confidential | Document ID | Apr 17. 1. 2017 .

PREVENTIVE MAINTENANCE PROCESS Confirmation of Order BASIC STEPS OF MAINTENANCE PROCESSES Go to T. Code – IW44 • Selection of Orders Select Header Menu • Execution of Orders Confirmation • Confirmation of Orders Select “via operation list” in Confirmation Menu • Technical Completion of Orders Selection of operation list appears Enter Plant Enter Order type Select from Drill Down Enter Reference date Enter Planner group Enter Status Exclusive in Multi CRTD. 1. 2017 . CNF . Selection List TECO & CLSD 70 Presentation Title | Confidential | Document ID | Apr 17.

2017 . PREVENTIVE MAINTENANCE PROCESS Execute by clicking button BASIC STEPS OF MAINTENANCE PROCESSES All relevant Orders with • Selection of Orders Operations will be copied on • Execution of Orders main screen • Confirmation of Orders • Technical Completion of Orders Select All Operations Click All Actual Data on Header Tool bar All Planning data of operations defaulted from relevant Orders Enter Actual Work Center Qty Flag Final confirmation. Clear all Res & No remaining work Enter Start Date & Time Enter End Date & Time 71 Presentation Title | Confidential | Document ID | Apr 17. 1.

2017 . PREVENTIVE MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE Enter Actual Duration PROCESSES • Selection of Orders Enter Confirmation Text • Execution of Orders System will calculate Actual • Confirmation of Orders Duration • Technical Completion of Orders Save Confirmation by clicking Move to SAP Screen 72 Presentation Title | Confidential | Document ID | Apr 17. 1.

IW32 • Selection of Orders • Execution of Orders Selection of Order Screen • Confirmation of Orders appeared • Technical Completion of Orders Flag In process check box Enter Order Type PM01 Enter Period (Date from…to…) Enter Status exclusive in CRTD. REL . PREVENTIVE MAINTENANCE PROCESS Technical Completion of Order BASIC STEPS OF MAINTENANCE PROCESSES Go to T. 1. 2017 . Multiple Selection TECO & CLSD Enter Maintenance Plant Enter Planner group for Order Select from Drill Down Execute by clicking button 73 Presentation Title | Confidential | Document ID | Apr 17. Code .

PREVENTIVE MAINTENANCE PROCESS Order list of relevant section Appears BASIC STEPS OF MAINTENANCE PROCESSES Select order and click • Selection of Orders • Execution of Orders Order Main Header Screen • Confirmation of Orders Opens • Technical Confirmation of Click Settlement Rule button Orders Enter / change cost center & give % if required Click Flag of Technical Completion Enter Reference Date & Time Click Enter Button Order is Technically Completed & System Status Changed to TECO Move to SAP Screen 74 Presentation Title | Confidential | Document ID | Apr 17. 1. 2017 .

External Repair/Services • Technical Completion of Orders • Execution & Completion of 7. 2017 . Work shop Repair • Confirmation of Orders 6. Calibration Notification • Why-Why Analysis 75 Presentation Title | Confidential | Document ID | Apr 17. Break down Maintenance • Creation of PM02-Order 3. Shut down Maintenance • Selection of Order 4. Condition base Maintenance • Execution of Orders 5. Preventive Maintenance • Creation of M2-Notification • Selection of M2-Notification 2. BREAKDOWN MAINTENANCE PROCESS BASIC PROCESSES BASIC STEPS OF BREAKDOWN MAINTENANCE PROCESS 1. 2.

2. Code – IW21Create • Creation of M2-Notification Notification • Selection of M2-Notification Select from Drill Down Enter Notification Type • Creation of PM02-Order H/L TO N/F Types • Selection of Order Do not Enter Notification System Generated Number • Execution of Orders • Confirmation of Orders Notification Tab Screen Appears • Technical Completion of Orders • Execution & Completion of Click Enter Button Notification • Why-Why Analysis Enter Notification Description Enter Equipment / FL / Assembly (as required) Enter Reported By (Name) 76 Presentation Title | Confidential | Document ID | Apr 17. 2017 . BREAKDOWN MAINTENANCE PROCESS Creation of M2 Notification Manual Process BASIC STEPS OF MAINTENANCE PROCESSES Go to T.

77 Presentation Title | Confidential | Document ID | Apr 17.MAINTENANCE REQUEST This Notification type indicates a request made by Customer department to his Supplier/Service Provider.g Request made by Raw Mill Mechanical for repair of Gear Box shaft on Workshop. E.  M1 --. 2017 . anybody can raise this Notification if it satisfies above condition.  M2 --. This includes all types of jobs of Maintenance/Repair/Service requests made by User on Service Provider EXCEPT Malfunction/Breakdown. However .. NOTIFICATION TYPES Continued.MALFUNCTION/BREAKDOWN This Notification Type is exclusively for information regarding Breakdown of Equipments This Notification is raised generally by Production on relevant Maintenance Department as a FIR of Unplanned stoppage in Production Process.

78 Presentation Title | Confidential | Document ID | Apr 17.ABNORMALITY RECORD • This notification is raised to register 7 types of Basic Defects in Equipments. if not corrected in time. to the relevant department responsible for such condition for necessary corrective action. 2017 .  M4 --. These defects are revealed through Daily Check List/ Inspection/Plant Round Satisfies the WCM requirement to monitor 7 type of basic defects which are responsible for Breakdown .UNSAFE CONDITION/ACCIDENT • This Notification is an information from any department including Safety regarding prevailing Unsafe/ Hazardous Condition which is dangerous and may cause damage to Property/Human being / Environment /Surroundings etc . NOTIFICATION TYPES Continued..  M3 --.

 M5: RECOMMENDATION/IMPROVEMENT •This Notification is generated by User for any improvement/development to be implemented . 2017 .WORK REQUEST-WORKSHOP • This notification is raised by User on workshop requesting its services for Repair/Machining/Replacement of Spares/Assembly/Equipment etc.. NOTIFICATION TYPES Continued. • The source for Improvement/Modification/Development in Reliability/ Availability /Maintainability may be WHY-WHY Analysis. 79 Presentation Title | Confidential | Document ID | Apr 17. Experts/Consultants recommendation/Other Units/KIP’s etc • The number of such Notifications will be an indicator of improvements done by User • These notifications will give List of Improvements done by User which is required by WCM or for sharing with other Units.  M6 --.

•Notification which does not fall in any of the conditions mentioned above may be raised in this type. NOTIFICATION TYPES Continued.  M8: MEASURING POINT ERROR •This notification is raised by the SAP system automatically whenever the Parameter defined as a Measuring Point deviates from its Standard Value or goes beyond its Acceptable Permissible Value.  M7: GENERAL NOTIFICATION. 2017 . •This type of Notification should not be used as far as possible as it will affect history/vital information about Equipments. 80 Presentation Title | Confidential | Document ID | Apr 17..

W. B/Down 2000000000 to 2999999999 M3 UnsafeCond. 2017 . Notification Types Notification Type Description Number Ranges From -To M1 Maintenance Request 1000000000 to 1999999999 M2 Malfunction./Accident 3000000000 to 3999999999 M4 Abnormality Record 4000000000 to 4999999999 M5 Recommendation 5000000000 to 5999999999 M6 Work Request.Shop 6000000000 to 6999999999 81 Presentation Title | Confidential | Document ID | Apr 17.

2. 2017 . BREAKDOWN MAINTENANCE PROCESS Creation of M2 Notification Manual Process BASIC STEPS OF MAINTENANCE PROCESSES Go to T. Code – IW21Create • Creation of M2-Notification Notification • Selection of M2-Notification Select from Drill Down Enter Notification Type • Creation of PM02-Order H/L TO N/F Types • Selection of Order Do not Enter Notification System Generated Number • Execution of Orders • Confirmation of Orders Notification Tab Screen Appears • Technical Completion of Orders • Execution & Completion of Click Enter Button Notification • Why-Why Analysis Enter Notification Description Enter Equipment / FL / Assembly (as required) Enter Reported By (Name) 82 Presentation Title | Confidential | Document ID | Apr 17.

M2 Type Notifications will be Generated by System thru breakdown entry made by CCR Naviaget >SAP Screen 83 Presentation Title | Confidential | Document ID | Apr 17. BREAKDOWN MAINTENANCE PROCESS Popup Massage of warranty If equipment Under BASIC STEPS OF warranty Prompts MAINTENANCE PROCESSES • Creation of M2-Notification Enter Code of STD TEXT Attached • Selection of M2-Notification • Creation of PM02-Order Main Work center/ Planner All information Defaulted Group etc Defaulted & can be from equipment master • Selection of Order Changed If Required • Execution of Orders If Reqd Enter Long Text • Confirmation of Orders • Technical Completion of Orders Go To Location Data Tab • Execution & Completion of Notification Flag breakdown check box • Why-Why Analysis Release & Save the Notification In case of Main Plant. 2. 2017 .

2. BREAKDOWN MAINTENANCE PROCESS Selection of M2 Notification BASIC STEPS OF MAINTENANCE PROCESSES Go to T. SAP Screen . Code – IW28 Selection of Notification • Creation of M2-Notification • Selection of M2-Notification Flag check box Outstanding or In process (as Reqd) • Creation of PM02-Order • Selection of Order Enter Notification Date • Execution of Orders Enter Planner group • Confirmation of Orders Select from Drill Down • Technical Completion of Orders Enter Maintenance Plant • Execution & Completion of Click Enter Button Notification • Why-Why Analysis List of Notifications Appears as per Selection Criteria Select relevant Notification Click on Details Button Notification Change Screen Appears 84 Presentation Title | Confidential | Document ID | Apr 17. 2017 Navigate.

Preventive Maintenance” Navigate> SAP Screen 85 Presentation Title | Confidential | Document ID | Apr 17. 2. 2017 . BREAKDOWN MAINTENANCE PROCESS Creation of PM02 Type Order BASIC STEPS OF from Notification MAINTENANCE PROCESSES • Creation of M2-Notification M2 Notification selected in Changed Mode as explained in • Selection of M2-Notification pervious sheet • Creation of PM02-Order Click Create button • Selection of Order • Execution of Orders of Order Tab • Confirmation of Orders Create Order Popup Screen • Technical Completion of Orders Appears with Defaulted data from notification • Execution & Completion of Enter PMActType BDM & click Select from Drill Down Notification continue button & save • Why-Why Analysis Breakdown Order Created Further process of order will remain same as explained in process “1.

Preventive Maintenance” • Selection of Order • Execution of Orders • Confirmation of Orders • Technical Completion of Orders • Execution & Completion of Notification • Why-Why Analysis 86 Presentation Title | Confidential | Document ID | Apr 17. BREAKDOWN MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE PROCESSES Process of Selection of Order. 2. 2017 . confirmation & TECO will be similar to processes • Selection of M2-Notification explained in process “ • Creation of PM02-Order 1. • Creation of M2-Notification Execution of Order.

BREAKDOWN MAINTENANCE PROCESS Execution of M2 Notification BASIC STEPS OF (Order not generated) MAINTENANCE PROCESSES • Creation of M2-Notification M2 Notification selected in Changed Mode as explained in • Selection of M2-Notification pervious Process • Creation of PM02-Order To Attach Std Text Go to Effect Select from Drill Down • Selection of Order field & select relevant code of Std Text • Execution of Orders • Confirmation of Orders Insert Text popup screen • Technical Completion of Orders appears. 2017 . enter Text ID – ST & click on dropdown of • Why-Why Analysis Text Name field Next Popup screen Database selection for SAP script text Execute Popup screen Database selection for SAP script text without entering any data 87 Presentation Title | Confidential | Document ID | Apr 17. • Execution & Completion of On Insert Text screen Flag Select from Drill Down Notification Expand immediately . 2.

2017 . Select relevant text & click continue • Creation of M2-Notification button • Selection of M2-Notification • Creation of PM02-Order Now popup screen Insert Text appear again with text attached. Complete it & go back to main screen • Execution & Completion of Notification Select malfunction& downtime tab and Enter down time end • Why-Why Analysis Date &Time. 2. BREAKDOWN MAINTENANCE PROCESS BASIC STEPS OF Next Popup screen Find SAP Select from Drill Down MAINTENANCE PROCESSES script text will appear. Click Complete Flag and complete Notification Navigate> SAP Screen 88 Presentation Title | Confidential | Document ID | Apr 17. • Selection of Order Click Continue Button • Execution of Orders • Confirmation of Orders Desired Standard Text Get • Technical Completion of Orders copied in long text.

ZRPM-WHY • Selection of M2-Notification • Creation of PM02-Order Enter Plant . 2017 . Plant Section & Select from Drill Down Planner group • Selection of Order • Execution of Orders Enter Date Range (From. 2. Code -..To…) • Confirmation of Orders Select status by flagging and • Technical Completion of Orders execute • Execution & Completion of Notification List of Notification appears (as per selection criteria) • Why-Why Analysis Select relevant notification & double click it Why Why Analysis screen Appears 89 Presentation Title | Confidential | Document ID | Apr 17. BREAKDOWN MAINTENANCE PROCESS BASIC STEPS OF Create Why Why Analysis MAINTENANCE PROCESSES Sheet • Creation of M2-Notification Go to T..

2. 2017 . BREAKDOWN MAINTENANCE PROCESS BASIC STEPS OF Enter Object Code Select from Drill Down MAINTENANCE PROCESSES Enter Damage Code Select from Drill Down • Creation of M2-Notification • Selection of M2-Notification Enter all Possible Causes Select from Drill Down • Creation of PM02-Order (Possible reasons) • Selection of Order Flag YES box to actual Cause • Execution of Orders • Confirmation of Orders Enter Observations • Technical Completion of Orders Enter Analysis In Why Why • Execution & Completion of Field Notification Enter Rectification carried out • Why-Why Analysis Enter Recommendations Enter Responsible person and Tar Date for Recommendations Select Document Attached - Say 2 90 Presentation Title | Confidential | Document ID | Apr 17.

2. 2017 . BREAKDOWN MAINTENANCE PROCESS BASIC STEPS OF Next procedure of Standard text shall be similar as explained in MAINTENANCE PROCESSES Process “ Execution of M2 • Creation of M2-Notification Notification” • Selection of M2-Notification Click Complete Flag and • Creation of PM02-Order Complete Notification • Selection of Order Save why-why Analysis • Execution of Orders • Confirmation of Orders Change Why Why Analysis • Technical Completion of Orders Go to T. Code – ZRPM_WHY • Execution & Completion of Notification Go to Main screen of selected • Why-Why Analysis Notification’s why why analysis Click “Put in Process” Flag Change Why Why analysis data as per requirement Save changed why-why Navigate> SAP Screen Analysis 91 Presentation Title | Confidential | Document ID | Apr 17.

Shut down Maintenance Orders 4. Calibration Request (Indent) • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 92 Presentation Title | Confidential | Document ID | Apr 17. External Repair/Services Order • Creation of Direct Purchase 7. 2017 . Condition base Maintenance • Report of Shutdown Planning 5. Break down Maintenance Orders • Selection of PM03 .Shutdown 2. SHUTDOWN MAINTENANCE PROCESS BASIC PROCESSES BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS 1.Shutdown 3. Work shop Repair • Creation of Direct Purchase 6. Preventive Maintenance • Creation of PM03 . 3.

Shutdown Go to T. Code – IW31 Orders Enter Order Type . 3.M Select from Drill Down Request (Indent) • Report of Shutdown Planning Maintenance Plant Select from Drill Down • Execution of Orders Enter plant Section Select from Drill Down • Confirmation of Orders Enter Planner Group Select from Drill Down • Technical Completion of Orders Click Execute Button 93 Presentation Title | Confidential | Document ID | Apr 17. SHUTDOWN MAINTENANCE PROCESS BASIC STEPS OF SHUTDOWN Creation of Shutdown Order MAINTENANCE PROCESS • Creation of PM03 .Shutdown Enter Equipment Number By Drill Down go to Orders selection screen • Report of Shutdown Planning Equipment selection screen appears • Creation of Direct Purchase Order Enter Equipment Class (Optional) Select from Drill Down • Creation of Direct Purchase Equipment Category . 2017 .PM03 Select from Drill Down • Selection of PM03 .

Shutdown Create Shutdown Orders Maintenance Order : Central Header Screen appears • Report of Shutdown Planning • Creation of Direct Purchase Enter Order Description Order Go to Header data Tab & Enter • Creation of Direct Purchase PMActTYPE . SHUTDOWN MAINTENANCE PROCESS Select Desired Equipment & BASIC STEPS OF SHUTDOWN click . 3.Shutdown Orders Enter Planning Plant & Enter Select from Drill Down • Selection of PM03 . Equipment entered in MAINTENANCE PROCESS field • Creation of PM03 . 2017 .SDM Request (Indent) Go to Operation Tab and Enter • Execution of Orders Operations as required • Confirmation of Orders Enter Relevant Work Center Select from Drill Down • Technical Completion of Orders Enter Relevant Control key Better to Create Separate Order for PMIN & PMEX Control key Pl Refer Next Slide 94 Presentation Title | Confidential | Document ID | Apr 17.

2017 . PMIN PMEX After Assigning Control Keys Enter Work or Duration Select Operations Enter WC Qty and Cal. from Drill from Drill click S.Loc (see stock) & Batch Down Down External Processing operation Again Go to Operation screen Select from Drill Appears Enhancement Button and enter Field key – ZPM0001. Down Go to service tab & Select Select Position from Drill Desired Services from Service Master or write Description only Down Click Gen Data Button & Get & Enter Required Quantity Reservation Number on comp detail screen & come back Enter Cost Element & Press Enter 95 Presentation Title | Confidential | Document ID | Apr 17. from Drill Required Group Down Select Enter Vender .Key Click on External Button Popup screen External Activity type Defaulted Processing Operation appears Select Operation & Go to Select Material Group ( S524 Select Component TAB if Material For External Services) & Pur. tracking No & Select Enter required Material. qty.

2017 . Enter Dept and Press Enter Save Order by click button Repeat above three steps for Navigate> SAP Screen Next Operation's Go to Header Screen & Click Determine cost button You can See PR No Thru GEN For Release Order Press Icon data->Act data Tab Save order by click button Navigate> SAP Screen 96 Presentation Title | Confidential | Document ID | Apr 17. Click scheduling & determine Enter Cost Element & Press cost button Enter Create Purchase Requisition For Release Order Press Icon screen appears.

3. 2017 . SHUTDOWN MAINTENANCE PROCESS BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS • Creation of PM03 . • Report of Shutdown Planning confirmation & TECO will be • Creation of Direct Purchase similar to processes Order explained in process “ • Creation of Direct Purchase 1. Execution of Order. Preventive Maintenance” Request (Indent) • Report of Shutdown Planning • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 97 Presentation Title | Confidential | Document ID | Apr 17.Shutdown Orders • Selection of PM03 - Shutdown Orders Process of Selection of Order.

3. of Shutdown BASIC STEPS OF SHUTDOWN Planning MAINTENANCE PROCESS Go to T. SHUTDOWN MAINTENANCE PROCESS Report1. 2017 .Shutdown Orders Display order & Operation: selection of order & Operation • Selection of PM03 .Shutdown screen appears Orders • Report of Shutdown Planning Flag Outstanding & In process Order • Creation of Direct Purchase Order Enter Order type Select from Drill Down • Creation of Direct Purchase Enter Main work center Select from Drill Down Request (Indent) • Execution of Orders Enter Period (dates) • Confirmation of Orders Maintenance Plant Select from Drill Down • Technical Completion of Orders Enter Plant Section Select from Drill Down Enter Planner Group Select from Drill Down 98 Presentation Title | Confidential | Document ID | Apr 17. Code – IW49N • Creation of PM03 .

Shutdown Report of Order with Operation etc Appears Orders • Selection of PM03 . 3. 2017 .Shutdown View Reports with Relevant Layout selection Orders • Report of Shutdown Planning Navigate> SAP Screen • Creation of Direct Purchase Order • Creation of Direct Purchase Request (Indent) • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 99 Presentation Title | Confidential | Document ID | Apr 17. SHUTDOWN MAINTENANCE PROCESS BASIC STEPS OF SHUTDOWN Click Execute Button MAINTENANCE PROCESS • Creation of PM03 .

SHUTDOWN MAINTENANCE PROCESS Report 2 of Shutdown BASIC STEPS OF SHUTDOWN Planning (MATERIAL) MAINTENANCE PROCESS • Creation of PM03 -Shutdown Go to IWBK – Material Availability Check (for orders) Orders • Selection of PM03 -Shutdown Material availability Information screen Orders • Report of Shutdown Planning Click Multiple Selection of Order • Creation of Direct Purchase Field Order Click Multiple selection button Select from Drill Down • Creation of Direct Purchase Request (Indent) Flag outstanding & In process • Execution of Orders Enter Order Type. 2017 . 3.PM09 • Confirmation of Orders • Technical Completion of Orders Enter Period (dates) Maintenance Plant Select from Drill Down Enter Plant Section Select from Drill Down Enter Planner Group Select from Drill Down 100 Presentation Title | Confidential | Document ID | Apr 17.

3. SHUTDOWN MAINTENANCE PROCESS
Click Execute Button
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS Report of Order with Operation
• Creation of PM03 -Shutdown etc Appears
Orders
Go to back to Multiple selection
• Selection of PM03 -Shutdown screen & Execute
Orders
• Report of Shutdown Planning Paste Selected Orders &
execute
• Creation of Direct Purchase
Order You will reach back to main
screen of Material availability
• Creation of Direct Purchase Information
Request (Indent)
• Execution of Orders Click execute button again

• Confirmation of Orders Screen of “Availability list of
• Technical Completion of Orders Materials for Operations” will
appears

On This Screen You Will Get
Order wise Materials with Stock
Navigate> SAP Screen
Availability status

101 Presentation Title | Confidential | Document ID | Apr 17, 2017

3. SHUTDOWN MAINTENANCE PROCESS
Creation of Direct Purchase
BASIC STEPS OF SHUTDOWN Order (For Contractors)
MAINTENANCE PROCESS
• Creation of PM03 -Shutdown Go to T. Code ME21N –Create
Purchase Order
Orders
• Selection of PM03 -Shutdown Select Type of Purchase Order Select from Drop Down

Orders
Enter Vendor Code Select from Drop Down
• Report of Shutdown Planning thru Vendors : Purchasing

• Creation of Direct Purchase Enter Purchase Organization,
Purchase Group & Company Select from Drop Down
Order (For Contractors) Code
• Creation of Direct Purchase
Go to item overview Tab and
Request (Indent) Select from Drop Down
Enter Account Assignment – K
• Execution of Orders and Item category - D
• Confirmation of Orders
Enter Short text of Services
• Technical Completion of Orders
Enter Material Group , Plant , Select from Drop Down.
tracking number (Employee) Search Tracking number
and Department (planner group) thru “Vendor by Company
code”

102 Presentation Title | Confidential | Document ID | Apr 17, 2017

3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS Go to Item Tab and Enter Select from Drop Down
Services number , Qty
• Creation of PM03 -Shutdown
Orders Go to Account Assignment Sub Select from Drop Down
Tab and Enter G/L Account
• Selection of PM03 -Shutdown number and Cost center
Orders
• Report of Shutdown Planning Check entries by Clicking
Button
• Creation of Direct Purchase
Order (For Contractors) Correct Entries If error massage
other wise Save the order
• Creation of Direct Purchase
Request (Indent) Navigate> SAP Screen
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders

103 Presentation Title | Confidential | Document ID | Apr 17, 2017

4. Work shop Repair • Selection of M8 type Notification 6. External Repair/Services • Creation of Corrective Maintenance 7. Shut down Maintenance Auto Notification 4. CONDITION BASE MAINTENANCE PROCESS BASIC PROCESSES BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS 1. Break down Maintenance • Creation of Measuring Document & 3. Calibration Order Thru Notification • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 104 Presentation Title | Confidential | Document ID | Apr 17. 2017 . Condition base Maintenance • Creation of Entry List • Measuring Document Thru Entry list 5. Preventive Maintenance • Creation of Measuring Point • Selection of Measuring Point 2.

SHUTDOWN MAINTENANCE PROCESS Creation of Direct Purchase BASIC STEPS OF SHUTDOWN Requisition (For Spare) MAINTENANCE PROCESS • Creation of PM03 -Shutdown Go to T. code ME51N -Create Orders PR • Selection of PM03 -Shutdown Enter PR Type & Header note Select from Drop Down Orders Account Assignment Type – U & Select from Drop Down • Report of Shutdown Planning Item Category leave Blank • Creation of Direct Purchase Order (For Contractors) Enter Material & Reqd Qty Select from Drop Down • Creation of Direct Purchase Enter Del date . 3. 2017 . Plant & Request (Indent) Tracking number (planner Select from Drop Down group) • Execution of Orders • Confirmation of Orders Check entries by Clicking Button • Technical Completion of Orders Correct Entries If error massage other wise Save the Purchase request Navigate> SAP Screen 105 Presentation Title | Confidential | Document ID | Apr 17.

CONDITION BASE MAINTENANCE PROCESS BASIC STEPS OF CONDITION Creation of Measuring Point BASE MAINT. 4. PROCESS Go to T. 2017 . Code .IK01 -Crete • Creation of Measuring Point Measuring Point • Selection of Measuring Point • Creation of Measuring Select Measuring Point Object - IEQ Document & Auto notification • Creation of Entry List Select & enter Equipment • Measuring Document Thru number Entry list Select Relevant Measuring • Selection of M8 type Point Category (Except L & F) Notification Do not flag MP as counter for • Creation of Corrective CBM Maintenance Order Thru Click on Enter Button Notification • Execution of Orders Write Measuring Position & • Confirmation of Orders Description • Technical Completion of Orders 106 Presentation Title | Confidential | Document ID | Apr 17.

2017 . PROCESS (UOM & decimal Place • Creation of Measuring Point defaulted) • Selection of Measuring Point Go to Additional data Button • Creation of Measuring header tool bar Document & Auto notification Enter Upper range limit & Lower • Creation of Entry List range limit • Measuring Document Thru Click on Enter Button Entry list • Selection of M8 type Main screen appears. 4. Now click on Save button to save MP Notification • Creation of Corrective Navigate> SAP Screen Maintenance Order Thru Notification • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 107 Presentation Title | Confidential | Document ID | Apr 17. CONDITION BASE MAINTENANCE PROCESS BASIC STEPS OF CONDITION Enter relevant Characteristic BASE MAINT.

IK07 – Display • Creation of Measuring Point measuring Point : Measpoint • Selection of Measuring Point Selection • Creation of Measuring Enter Characteristics & MP Document & Auto notification Category • Creation of Entry List Click Execute Button • Measuring Document Thru Measuring point list appears Entry list • Selection of M8 type Notification Select relevant Measuring point • Creation of Corrective Navigate> SAP Screen Maintenance Order Thru Notification • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 108 Presentation Title | Confidential | Document ID | Apr 17. 2017 . PROCESS Go to T. CONDITION BASE MAINTENANCE PROCESS BASIC STEPS OF CONDITION Selection of Measuring Point BASE MAINT. 4. Code .

Code – IK11 . 2017 .Crete • Selection of Measuring Point Measuring Document • Creation of Measuring Document & Auto Notification Enter Measuring Point (as selected) • Creation of Entry List • Measuring Document Thru Again Click on Enter Button Entry list Enter MeasRdg as taken from • Selection of M8 type Notification site • Creation of Corrective Again Click on Enter Button Maintenance Order Thru Notification A Massage Appears In case • Execution of Orders Reading is Outside range • Confirmation of Orders • Technical Completion of Again Click on Enter Button Orders Main screen of M8 type Notification Generates Automatically 109 Presentation Title | Confidential | Document ID | Apr 17. PROCESS Document • Creation of Measuring Point Go to T. 4. CONDITION BASE MAINTENANCE PROCESS BASIC STEPS OF CONDITION Creation of Measuring BASE MAINT.

CONDITION BASE MAINTENANCE PROCESS BASIC STEPS OF CONDITION Enter Reported by & click Enter BASE MAINT. PROCESS button • Creation of Measuring Point An Auto Notification of M8 type • Selection of Measuring Point Created • Creation of Measuring A massage comes for Document & Auto Notification Measuring document Created • Creation of Entry List Navigate> SAP Screen • Measuring Document Thru Entry list • Selection of M8 type Notification • Creation of Corrective Maintenance Order Thru Notification • Execution of Orders • Confirmation of Orders • Technical Completion of Orders 110 Presentation Title | Confidential | Document ID | Apr 17. 2017 . 4.

Code – IK31 - • Creation of Measuring Point Measuring reading entry list: • Selection of Measuring Point Create • Creation of Measuring Click on Enter Button Document & Auto notification Screen of Measuring reading • Creation of Entry List entry list: Create Appears • Measuring Document Thru Enter entry list name & Entry list Description • Selection of M8 type Enter measuring point numbers Notification As selected from drop down list • Creation of Corrective Click on Enter Button Maintenance Order Thru All details of Measuring points Notification Appears in list • Execution of Orders Now Click on Save Button • Confirmation of Orders • Technical Completion of A Massage “ measurement Orders reading entry list xxx saved. CONDITION BASE MAINTENANCE PROCESS BASIC STEPS OF CONDITION Creation of Entry List BASE MAINT. 4. 2017 . Navigate> SAP Screen 111 Presentation Title | Confidential | Document ID | Apr 17. PROCESS Go to T.

Code – IK34 – • Creation of Measuring Point Collective entry of • Selection of Measuring Point MeasDocuments: Initial screen • Creation of Measuring Enter Entry list number Document & Auto notification Click on Enter Button • Creation of Entry List • Measuring Document Thru Collective entry of MeasDocuments: overview Entry list screen Appears • Selection of M8 type Enter measuring Reading in Notification relevant measuring point field • Creation of Corrective Click on Enter Button Maintenance Order Thru Notification A Massage Appears In case • Execution of Orders Reading is Outside range &click • Confirmation of Orders again enter button. M8 • Technical Completion of Notification will generate Orders A massage appears as xx Navigate> Measuring document Created SAP Screen 112 Presentation Title | Confidential | Document ID | Apr 17. CONDITION BASE MAINTENANCE PROCESS Creation of Measuring BASIC STEPS OF CONDITION Document Thru Entry list BASE MAINT. PROCESS Go to T. 4. 2017 .

REPAIR MAINTENANCE PROCESS BASIC PROCESSES BASIC STEPS OF REPAIR MAINTENANCE PROCESS 1. Break down Maintenance • Creation of PM09-Order 3. Preventive Maintenance • Creation of M6-Notification • Selection of M6-Notification 2. 5. Shut down Maintenance • Selection of Order 4. Calibration Notification 113 Presentation Title | Confidential | Document ID | Apr 17. 2017 . Condition base Maintenance • Execution of Orders 5. Work shop Repair • Confirmation of Orders 6. External Repair/Services • Technical Completion of Orders • Execution & Completion of 7.

Code – IW21Create • Creation of M 6-Notification Notification • Selection of M 6-Notification Enter Notification Type Select from Drill Down • Creation of PM09-Order H/L TO N/F Types • Selection of Order Do not Enter Notification Number System Generated • Execution of Orders • Confirmation of Orders Click Enter Button • Technical Completion of Orders • Execution & Completion of Notification Tab Screen Appears Notification Enter Notification Description Enter Equipment / FL / Assembly (as required) Enter Reported By (Name) Enter Code of STD TEXT Select from Drill Down Attached as per requirement 114 Presentation Title | Confidential | Document ID | Apr 17. 5. 2017 . REPAIR MAINTENANCE PROCESS Creation of M6 Notification Manual Process BASIC STEPS OF MAINTENANCE PROCESSES Go to T.

REPAIR MAINTENANCE PROCESS BASIC STEPS OF Main Work center/ Planner All information Defaulted MAINTENANCE PROCESSES Group etc Defaulted & can be from equipment master • Creation of M2-Notification Changed If Required • Selection of M2-Notification Write Details of Job in Long Text • Creation of PM02-Order • Selection of Order Go To Location Data Tab • Execution of Orders • Confirmation of Orders Save the Notification • Technical Completion of Orders • Execution & Completion of Navigate> SAP Screen Notification • Why-Why Analysis 115 Presentation Title | Confidential | Document ID | Apr 17. 5. 2017 .

2017 . REPAIR MAINTENANCE PROCESS BASIC STEPS OF Selection of M6 Notification MAINTENANCE PROCESSES • Creation of M6-Notification Go to T. 5. Code – IW28 Selection of Notification • Selection of M6-Notification • Creation of PM09-Order Flag check box Outstanding (as reqd) • Selection of Order • Execution of Orders Enter Notification Date • Confirmation of Orders Select Notification & Create • Technical Completion of Orders PM09 Type Order • Execution & Completion of Notification Click Create button of Order Tab Navigate> SAP Screen 116 Presentation Title | Confidential | Document ID | Apr 17.

Notification Select Relevant Work Center for Operator & Enter Number of Hours Go to Component TAB & Attach Required Material Navigate> SAP Screen 117 Presentation Title | Confidential | Document ID | Apr 17. 5. REPAIR MAINTENANCE PROCESS Create PM09 Type Order BASIC STEPS OF MAINTENANCE PROCESSES Select Relevant Maintenance Select from Drill Down • Creation of M6-Notification Activity Type( Always RVN) • Selection of M6-Notification Go to Operation TAB • Creation of PM09-Order • Selection of Order Select Relevant Work Center Select from Drill Down • Execution of Orders (Type 0001) • Confirmation of Orders Enter Number of Hours • Technical Completion of Orders • Execution & Completion of Other Field automatically Populated. 2017 .

REPAIR MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE PROCESSES • Creation of M6-Notification GO to IW38 & Search PM09 • Selection of M6-Notification Type Order • Creation of PM09-Order Navigate> SAP Screen • Selection of Order • Execution of Orders • Confirmation of Orders • Technical Completion of Orders • Execution & Completion of Notification 118 Presentation Title | Confidential | Document ID | Apr 17. 5. 2017 .

5. REPAIR MAINTENANCE PROCESS BASIC STEPS OF Release Order & Issue Required MAINTENANCE PROCESSES Material. • Creation of M6-Notification Carry out Repair Work As per • Selection of M6-Notification Request • Creation of PM09-Order • Selection of Order Navigate> SAP Screen • Execution of Orders • Confirmation of Orders • Technical Completion of Orders • Execution & Completion of Notification 119 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

5. REPAIR MAINTENANCE PROCESS BASIC STEPS OF Further process of order will MAINTENANCE PROCESSES remain same as explained in • Creation of M6-Notification process “1. 2017 . Preventive • Selection of M6-Notification Maintenance” • Creation of PM09-Order Navigate> SAP Screen • Selection of Order • Execution of Orders • Confirmation of Orders • Technical Completion of Orders • Execution & Completion of Notification 120 Presentation Title | Confidential | Document ID | Apr 17.

2017 . External Repair/Services • Technical Completion of Orders 7. Preventive Maintenance • Creation of PM09 Type Order • Selection PMEX Activity type 2. Shut down Maintenance Requisition 4. Condition base Maintenance • Creation Of Purchase Order 5. EXTERNAL REPAIR MAINTENANCE PROCESS BASIC PROCESSES BASIC STEPS OF EXTERNAL REPAIR MAINTENANCE PROCESS 1. Work shop Repair • Confirmation of External Service Entry Sheet 6. 6. Calibration 121 Presentation Title | Confidential | Document ID | Apr 17. Break down Maintenance • Creation of Purchase 3.

EXTERNAL REPAIR MAINTENANCE PROCESS BASIC STEPS OF EXTERNAL Creation of PM09 Type Repair REPAIR PROCESSES Order Select Relevant Type Select from Drill Down • Creation of PM09 Type Order Maintenance Activity (Always RVN. Tracking Number Enter & GO to External Processing operation Screen 122 Presentation Title | Confidential | Document ID | Apr 17. RWN) • Selection PMEX Activity type Go to Operation TAB • Creation of Purchase Requisition Select Control Key As PMEX Creation of Purchase Order Enter Operation & Select It • Confirmation of External Service Entry Sheet Click External Service Button • Technical Completion of Orders POP Screen Will Appear Enter Select from Drill Down Material Group S 524.Purchase Group. 6. 2017 .

Quantity & Unit • Creation of PM09 Type Order • Selection PMEX Activity type Write Desired Vendor Code • Creation of Purchase Enter Cost Element & click Select from Drill Down Requisition • Creation of Purchase Order Pop Screen of Purchase Select from Drill Down • Confirmation of External Service request Will Appear Enter Entry Sheet Department (i.e Main Planner • Technical Completion of Orders group) Go back to Order main screen Release it & Save Order Go to Change Mode of Order & select TAB Actual Data You will get PR number Navigate> SAP Screen 123 Presentation Title | Confidential | Document ID | Apr 17. 6. 2017 . EXTERNAL REPAIR MAINTENANCE PROCESS BASIC STEPS OF Write Short Text of External MAINTENANCE PROCESSES Service . Approximate Cost of Repair.

EXTERNAL REPAIR MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE PROCESSES Go To Change Mode of PR (ME52N) • Creation of PM09 Type Order GO To Document Overview & Selection PMEX Activity type Select Relevant PR • Creation of Purchase Requisition GO TO Customer TAB & Enter • Creation of Purchase Order all Required Deatils • Confirmation of External Service Entry Sheet Save PR • Technical Completion of Orders Navigate> SAP Screen 124 Presentation Title | Confidential | Document ID | Apr 17. 6. 2017 .

2017 . 6. EXTERNAL REPAIR MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE PROCESSES MM Will Prepare Purchase Order on PR • Creation of PM09 Type Order • Selection PMEX Activity type • Creation of Purchase Requisition • Creation of Purchase Order • Confirmation of External Service Entry Sheet • Technical Completion of Orders 125 Presentation Title | Confidential | Document ID | Apr 17.

EXTERNAL REPAIR MAINTENANCE PROCESS BASIC STEPS OF MAINTENANCE PROCESSES MM Will Prepare Service Entry Sheet • Creation of PM09 Type Order You will Accept Service Entry Sheet • Selection PMEX Activity type • Creation of Purchase Requisition • Creation of Purchase Order • Confirmation of External Service Entry Sheet • Technical Completion of Orders 126 Presentation Title | Confidential | Document ID | Apr 17. 2017 . 6.

• Creation of PM09 Type Order Save • Selection PMEX Activity type • Creation of Purchase Requisition • Creation of Purchase Order • Confirmation of External Service Entry Sheet • Technical Completion of Orders 127 Presentation Title | Confidential | Document ID | Apr 17. EXTERNAL REPAIR MAINTENANCE PROCESS BASIC STEPS OF This Type of Order to be TECO MAINTENANCE PROCESSES only When FINAL Service Sheet Made. 2017 . 6.

MANAGING REPORTS 128 Presentation Title | Confidential | Document ID | Apr 17. 2017 . III.

STANDARD REPORTS 1. Object Class Statistics [MCI1] Object breakdown analysis in terms of Maintenance cost Standard drill down (Key Figure) Assembly Construction year Manufacturer Material Object class Month 129 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

Standard drill down (Key Figure) Assembly Construction year Manufacturer Material Object class Month 130 Presentation Title | Confidential | Document ID | Apr 17. Manufacturer Analysis [MCI2] Object breakdown analysis in terms of Maintenance cost Manufacturer wise. STANDARD REPORTS 2. 2017 .

Location Analysis [MCI3] Object breakdown analysis in terms of Maintenance cost Location wise Standard drill down (Key Figure) Assembly Equipment Functional Location Location Maintenance plant Planner group Planning plant Plant section Month 131 Presentation Title | Confidential | Document ID | Apr 17. STANDARD REPORTS 3. 2017 .

STANDARD REPORTS 4. 2017 . Planner Group Analysis [MCI4] Object breakdown analysis in terms of Maintenance cost Planner Group wise Standard drill down (Key Figure) Assembly Equipment Functional Location Location Maintenance plant Planner group Planning plant Plant section Month 132 Presentation Title | Confidential | Document ID | Apr 17.

Damage Analysis [MCI5] Object Damage analysis in terms of Damage & Causes. Notification Type wise Standard drill down (Key Figure) Activity code Cause of damage CdGrp: damage cause Code group: activity Code group: damage Damage Equipment Functional Location Notification type Month 133 Presentation Title | Confidential | Document ID | Apr 17. Single Object . STANDARD REPORTS 5. 2017 .

STANDARD REPORTS

6. Object Statistics [MCI6]

This report provide the detail about the object statistics ( like
how many Equipment installed on a Function Location)

Standard drill down (Key Figure)

Object class
Manufacturer
Material
Construction year
Month

134 Presentation Title | Confidential | Document ID | Apr 17, 2017

STANDARD REPORTS

7. Breakdown Analysis [MCI7]

This report provide the Breakdown Analysis information
(No. of B/D, MTTR, MTBR etc.).

Standard drill down (Key Figure)

Equipment
Functional Location
Object class
Month

135 Presentation Title | Confidential | Document ID | Apr 17, 2017

STANDARD REPORTS

8. Cost Analysis [MCI8]

This report provide the Breakdown Analysis information
( No. of B/D, MTTR, MTBR etc.).

Standard drill down (Key Figure)

Equipment
Functional Location
Object class
Month

136 Presentation Title | Confidential | Document ID | Apr 17, 2017

). MTTR/MTBR Equipment [MCJB] This report provide : MTTR/MTBR Analysis Equipment wise( No. of B/D. Month wise Breakdown Statistics ( No. MTTR. 2017 . MTBR etc. STANDARD REPORTS 9. of Notifications & B/D Hrs) 137 Presentation Title | Confidential | Document ID | Apr 17.

2017 . MTBR etc. of B/D. STANDARD REPORTS 10. MTTR/MTBR Functional Location [MCJC] This report provide : MTTR/MTBR Analysis Equipment wise ( No. of Notifications & B/D Hrs) 138 Presentation Title | Confidential | Document ID | Apr 17. MTTR.) Month wise Breakdown Statistics ( No.

6.2 LIST OF DEVELOPED REPORTS 139 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

The No.Summary Report (Equipment wise) 2 Breakdown Matrix . following PLANT REPORTS are the Reports that are being developed in SAP: 1 List of Damage & Cause .Equipment ABC indicator & breakdown category wise 3 Work Center / Equipment wise Material Consumption 4 Equipment Schedule Maintenance Report 5 Breakdown why-why Analysis Report 6 PM order Skipped / Rescheduled Report 7 PM Order Slippage Summary Report ( Schedule Maintenance Slippage in Plant VC) 8 Preventive Maintenance Work Request Report 9 Motor Failure Report 10 Inspection Check List 140 Presentation Title | Confidential | Document ID | Apr 17. 2017 .LIST OF DEVELOPED REPORTS:  S.

LIST OF DEVELOPED REPORTS: S. No. PLANT REPORTS 11 Maintenance Order / Operation Pending List 12 Section / Equipment Performance Report 13 Equipment Lubrication Consumption Report 14 Quarterly Lubrication Consumption Report 15 Purchase Request Tracking Report 16 Equipment Maintenance Cost Report 17 List of Service Entry Sheets 18 Work Center Wise Service Cost Report 19 Shutdown (consolidated) Planning Report (resources & cost) 141 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

MINES REPORTS 20 Tyre Life Summary Report 21 Equipment Position Wise Tyre Run Report 22 Tyre Maintenance Register 23 Oil Consumption Report 24 Oil. Filter & Lubricant Monitoring Report 25 Assembly Life Details 26 Sub assembly Performance Report 27 Breakdown Summary 142 Presentation Title | Confidential | Document ID | Apr 17. 2017 .LIST OF DEVELOPED REPORTS: S.No.

143 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

Always use RUNNINGHOURS 144 Presentation Title | Confidential | Document ID | Apr 17. CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1 Crete Measuring Point.IK01 Measuring Point Object Select from Drop Down Select Equipment Select from Drop Down Select from Drop Down Select Relevant Measuring Point Category Flag for Measuring Point as a Counter Write Measuring Position Description Write Description of Measuring Point Select From Drop Attach Relevant CHARACTERISTICS Down . 2017 .

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2 Press Enter ICON Enter Counter Over Flow Reading Maximum Reading of Counter Enter Annual Estimate Reading It Will be drive Plan Press ICON For Save Message : “Measuring Point ………. Created THE END 145 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

CREATION OF MESURING POINT (LUB/Diesel Consumption) Sheet 1/2

Crete Measuring Point- IK01

Measuring Point Object Select from Drop Down

Select Equipment Select from Drop Down

Always Select Category
L- for Lubrication &
Select Relevant Measuring Point Category F- Fuel Consumption

Flag for Measuring Point as a Counter

Write Measuring Position Description

Write Description of Measuring Point

Select From Drop
Attach Relevant CHARACTERISTICS Down , ,Always LUB
CONCOSUMPTION…..

146 Presentation Title | Confidential | Document ID | Apr 17, 2017

CREATION OF MESURING POINT(LUB/Diesel Consumption) Sheet 2/2

Press Enter ICON

Don’t Enter Counter Over Flow Reading & Annual
Estimate Reading

Enter Save ICON Button

Message : “ Measuring Point ……..Created

Press ICON

Don’t Enter Counter Over Flow Reading & Annual
Estimate Reading

Enter Save ICON Button

Message : “ Measuring Point ……..Created
The END

147 Presentation Title | Confidential | Document ID | Apr 17, 2017

CREATION OF MESURING POINT Sheet 1/2

Crete Measuring Point- IK01

Measuring Point Object Select from Drop Down

Select Equipment Select from Drop Down

Select from Drop Down
Select Relevant Measuring Point Category

Press Icon

Write Measuring Position Description

Write Description of Measuring Point

Select From Drop
Attach Relevant CHARACTERISTICS Down

148 Presentation Title | Confidential | Document ID | Apr 17, 2017

Created THE END 149 Presentation Title | Confidential | Document ID | Apr 17. 2017 . CREATION OF MESURING POINT Sheet 2/2 Press Enter ICON Don’t Enter Counter Over Flow Reading & Annual Estimate Reading Enter Save ICON Button Message : “ Measuring Point ……...Created Press ICON Don’t Enter Counter Over Flow Reading & Annual Estimate Reading Enter Save ICON Button Message : “ Measuring Point …….

Created. THE END 150 Presentation Title | Confidential | Document ID | Apr 17. 2017 .. CREATION OF MESURING POINT DOCUMENT (IK11) Creation of Measuring Document IK11 Select Desired Measuring Point Select from Drop Down Enter ICON Button Next Screen will Appear for entering Reading Counter should be GREATER than Enter Counter Reading or Difference of Counter Previous Reading or Difference not more than 24 Hours Press ICON Button For Save Message : “Measuring Document …….

2017 . MAINTENANCE ITEM Continued. WITH TIME BASED PACKAGE 151 Presentation Title | Confidential | Document ID | Apr 17..

CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04 Create Maintenance Item IP04 Select from Drop Down Maintenance Plan Category Maintenance Strategy Select from Drop Down. Use Always GILDAY & GILMON Only Write Maintenance Item Description Select from Drop Down Enter Equipment Write ORDER Type This will be PM01 Always Select from Drop Down Maintenance Activity Type (Use PVM Or AMC ) Attach Relevant Task List 152 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

THE END 153 Presentation Title | Confidential | Document ID | Apr 17. CREATEING MAINTENANCE ITEM (TIME BASE) Sheet -2/2 For Selection of Task List Use Icon Task List Display Screen will Appear on Screen Flag General Task List Press Icon . Screen will appear with List of Task Lists Select Appropriate Task List Press Icon Enter Press Icon for Save You will get Message : Maintenance Item ( System Generated Number) Created. 2017 .

2017 . MAINTENANCE ITEM WITH PERFORMANCE BASED PACKAGE 154 Presentation Title | Confidential | Document ID | Apr 17.

2017 . CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2 Create Maintenance Item IP04 Maintenance Plan Category Select from Drop Down ALWAYS Use PERFHR Maintenance Strategy –For Plant.TPP.DG Equipment & MINHR – For Mines Equipment Write Maintenance Item Description Select from Drop Down Enter Equipment Write ORDER Type This will be PM01 Always Select from Drop Down Maintenance Activity Type Attach Relevant Task List 155 Presentation Title | Confidential | Document ID | Apr 17.

CREATE MAINTENANCE ITEM (PERFORMANCE BASE )Sheet -2/2 For Selection of Task List Use Button Task List Display Screen will Appear on Screen Flag General Task List Press Button . 2017 . Screen will appear with Task List Select Appropriate Task List Press Icon Press Icon for Save You will get Message : Maintenance Item ( System Generated Number) Created THE END 156 Presentation Title | Confidential | Document ID | Apr 17.

 NAVIGATE > SAP SCREEN  Creation of Maintenance Item-[IP04] 157 Presentation Title | Confidential | Document ID | Apr 17. 2017 .

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3 IP01 Create Maintenance Plan (IP01) Maintenance Plan Number is System Generated Number Maintenance Category Select from Drop Maintenance Strategy Down . 2017 .Always Use GILDAY & GILMON Press Icon Write Maintenance Plan Short Description Go to TAB For Assigning Maintenance Item POP Screen will appear Message : Possible Deletion of Data Entered When Selecting 158 Presentation Title | Confidential | Document ID | Apr 17.

Main Work Center & other field automatically Populated Main Planner Group . 2017 . CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 2/3 Display Maintenance Item :Selection Criteria Screen Will Appear .Main Work Center & other field automatically Populated from Equipment Master Press Icon Go to TAB “Maintenance Plan Scheduling Parameter Write Scheduling Period :365 Days Flag Fro Completion Requirement 159 Presentation Title | Confidential | Document ID | Apr 17.Main Work Center & other field automatically Populated from Equipment Master Main Planner Group .Write Equipment Number & Press Icon Main Planner Group .

Created The End 160 Presentation Title | Confidential | Document ID | Apr 17. CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 3/3 Press Icon For Save Pop Screen Will Appear For START DATE Select Radio Button “NO” Press Icon Message will Appear on Screen :” Maintenance Plan ………. 2017 .

2017 .Always Select PERFHR –For Plant. Maintenance Strategy DG. TPP & MINHR – For Mines Press Icon Write Maintenance Plan Short Description & Enter Counter Go to TAB For Assigning Maintenance Item POP Screen will appear Message : Possible Deletion of Data Entered When Selecting 161 Presentation Title | Confidential | Document ID | Apr 17. CREATION OF MAINTENANCE PLAN (PERFORMANCE BASE) Sheet 1/3 Create Maintenance Plan (IP01) Maintenance Plan Number is System Generated Number Maintenance Category Select from Drop Down .

Main Work Center & other field automatically Populated from Equipment Master Main Planner Group .Main Work Center & other field automatically Populated Main Planner Group .Main Work Center & other field automatically Populated from Equipment Master Press Icon Go to TAB “Maintenance Plan Scheduling Parameter Write Scheduling Period :365 Days Flag For Completion Requirement 162 Presentation Title | Confidential | Document ID | Apr 17. 2017 . CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 2/3 Display Maintenance Item :Selection Criteria Screen Will Appear .Write Equipment Number & Press Icon Main Planner Group .

CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 3/3 Press Icon For Save Pop Screen Will Appear For START Counter Reading Select Radio Button “NO” Press Icon Message will Appear on Screen :” Maintenance Plan ………. 2017 .Created The End 163 Presentation Title | Confidential | Document ID | Apr 17.