SAP PM CAPABILITITES

Road Map Towards Risk

Based Maintenance

June 21, 2023

 Objective

• To discuss effective utilization of SAP PM to adopt Risk Based Best

Maintenance Practices.

• To make SAP PM processes more user friendly.

2
 Background Problems
• SAP PM is currently not effectively being utilized as CMMS at our plants.

• SAP PM at FFC is required to be restructured as per standards and best industry

practices.

 Asset Register is required to be structured in line with ISO 14224.

 Review of SAP catalogues required for e.g. damage and cause code, Task lists in
light of ISO 14224 standard.

 The Notification and work order type are not unified with industry practices which
makes it challenging to monitor Maintenance performance.

• Missing Assets Information in Asset Register

• Missing mandatory field in notification/workorder

 Background Problems (Continued)
• Maintenance KPI to be monitored on dashboards.

• Improper Notification types are selected during initiation

• Preferred notifications priority is routine High.

• Incorrect Functional Locations /Equipment in Notifications.

• Notification workflows not followed.

• Notification not raised and job being done on Workorder only

• Maintenance history not maintained in SAP

• PMP overdue date can be tempered in the existing system

 Background Problems (Continued)

• Issuance of material in improper work orders.

• BOMs are missing / not updated

• Spare interchangeability is not available

• Missing Assets in Asset Register.

 SAP PM Capabilities Utilization Road Map
Phase-I Target Date
Re-organizing Plant Maintenance Work Types & Order Priorities
Notifications/order workflows Simplification Aug 2023
Notification / Workorder Essential - SAP Training - I
SAP Data Stewardship
Sep 2023 ~
Maintenance KPIs Monitoring / Dashboards Configuration

Phase-II Target Date

Asset Criticality Analysis Mar 2024
SAP PM Catalogues Populating as per ISO 14224
Apr 2024
Processing Failure Notification/Mandatory Fields – SAP Training - II

Phase-III Target Date

Asset Register re-structuring as per ISO 14224
Linking BoM with Assets and defining ICs
SAP PM Notification/Order complete with Task list / MPs Dec 2024
Integration of All Assets (RBI) with SAP
Eclass standard Taxonomy for Plant spare parts
Phase-I
 Unifying Notification / Workorder Types with Industry

Existing Notification and workorder types required to be in line with best

industry practices/Benchmarks* to:

a) Improve end user experience in selecting notification/order type

b) Monitor maintenance performance / benchmarking KPIs.

*Benchmarks:
SMRP- Society for Maintenance & Reliability PMO Model from EPRI
Professionals
Saudi Aramco Saudi Electric Company
Saudi power Plants
 Unifying Notification / Workorder Types with Industry

TYPE DESCRIPTION SUB-TYPES/REMARKS

PM PREVENTIVE ORDER SUB-TYPES:

 PMN (Time based)
 LOS (Performance Based)
 Calibration
 Warehouse Spares PM

PDM PREDECTIVE ORDER T&I Thickness Monitoring, Electrical Testing etc.

CM CORRECTIVE MAINTENANCE ORDER SUB-TYPES:

 Run-to-failure (RTF)
 Identified as Malfunction
 Identified from PM/PdM

PAM PROACTIVE MAINTENANCE ORDER SUB-TYPES:

 Improvement
 Modification (OPEX or CAPEX)
 Unifying Notification / Workorder Types with Industry

TYPE DESCRIPTION SUB-TYPES/REMARKS

PMS Shut Down / Turn Around Orders SUB-TYPES:

 Turn Around Jobs (Repetitive)
 Shutdown Jobs (Repetitive)
 Shutdown Jobs (Non Repetitive)
 Turn Around Jobs (Non Repetitive)

SS SUPPORT SERVICES ORDER SUB-TYPES:

 Workshop Services : For equipment sent directly to workshops, order can be
triggered from PM/CM/PAM
 Vehicle Request : Pool Management
 Quality Notification: Lab related services

OTR Others  Housekeeping related

 Issuance of Consumables
 Buildings /Offices /Facilitates PM /CM
 Weather Management System
Work Center Customization

Existing Work Center: 410 Entries

 Simplification of Notification Workflow

• SAP inbox related workflows for notifications are recommended to be

discontinued.

• For Emergency Notifications, the workorder shall be created first by

maintenance (on verbal approval by in-charge) and then related notification
will be generated by concerned Unit.
Selected KPIs for Dashboard

1 Proactive to Reactive Ratio

2 Pending & Overdue Notifications

3 Pending & Overdue Workorders

13
Monitoring Only (Non-KPI)

1 Mean Time Between Failure (MTBF)

2 Maintenance Cost

14
Phase-II
 Asset Criticality Analysis

SAP ABC Indicator

• A – Safety Critical
The most important consequence of failure is loss of containment of HAZMAT
with the possibility of causing a Major Accident Hazard (MAH). The elements that
safeguard this integrity are called Safety Critical Equipment.

• B- Business Critical
The next important consequence of failure is loss of operational functionality.
Such consequences are economic (production and/or maint. cost) in broad sense

• C - Non Critical
‘C’- priority asset is allowed to fail because it has virtually no direct impact on
production/safety. 
SAP Catalogues Populating as per ISO 14224
THANK YOU
THANK YOU
THANK YOU
 Unifying Notification / Workorder Types with Industry

Notification Types Workorder Types Maint Activity / Sub Type

Failure Data Requirements