Workshop Plant Maintenance

with SAP PM

Assets
What are we
talking about?

sales
view

technical
view

SAP
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Main aspects of the PM System

Structuring assets/material data

Planning

Implementation /
Documentation

History /
analyses

of maintenance steps

Techincal view

Sales view

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Integrated maintenance with PM

Module PM
Maintenance

Module FI
Assets accounting

Module MM
Materials administrationn

Module CO/IM
Controlling und
investment management

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Integration with the FI module

Asset number

Financial accounting
PM Objects

Assets
Real accounts

Real accounts bookings

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Integration with the CO module

poviding cost center
Time confirmation

Planning the rates for

internal activity using

Actual costs

activity types

Rates (in-plant
hourly rates)

Billing object
Cost center or
asset
Assets account
Other order
PSP Element

PM Order

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Integration with the MM module

Inventory management

Ordering

Order request for

external service or material

PM Order

Purchase commitments

Goods receipt

Invoice receipt

Invoice
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Master data in maintenance

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Installation structure

Functional location
 Installation location of a technical object

Equipment
 An individual, physical unit installed at a
functional location, which requires individual maintenance

Assembly
 (Stock) material, which can be used as a structural element in a system

Bill of material (BOM)

 A BOM gives structure to a functional location, equipment or an assembly as seen
by maintenance

Classes/ Attributes
 With the help of classes/attributes freely defined data can be associated with
functional locations and equipment
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Structuring / Hierarchy
Functional
location

Equipment

Assembly

Spare part
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Anlagenstruktur
Funct.location
Funct.location
Hierarchy
Funct.location
Insatalled
Equipment

Equipment

Equipment
Hierarchy
Equipment
Equipment/ FL
BOM
Assembly

Spare part

Assembly
BOM

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Functional location
Definition

An element in a technical structure = assets area at which

equipment can be installed

individual maintenance history

hierarchical setup

classifiable

bills of material

Order processing
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Functional location
Usage

Arrangement of functional locations by

functional criteria (press, die...)
process-oriented criteria (condensation...)
spacial criteria (buildings...)

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Functional location
Data transfer

Functional locations
Structuring data
Planning data
Location data
Allocation data

hierarchical
Data transfer

subordinate func. locations

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zugeordnete Equipments

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Equipment
Definition

An individual, physical unit which requires

its own maintenance.

individual maintenance history

classifiable

Set up at a functional location

BOMs / task schedules

scheduled maintenance possible

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Instandhaltungsauftrge
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Equipment
Examples

Equipment = an independent maintainable

technical asset

Plant components (pumps, motors, compressors...)

Production resources (cranes, tools...)

Vehicles

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Equipment
Usage

Planning future maintenance activities

Proof of completed PM activities

individual cost monitoring

technical history of objects

Proof of spare parts
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PM assembly

represents a type of device

is not tracked separately

uses BOMs to sort equipment according to design aspects

can also be a storage part

can be used to more-closely specify the following

PM notifications

PM orders

Task lists

Maintenance plans

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the Infosystem
can be used to analyze it

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Bill of materials (BOMs)

Structuring
A BOM gives equipment a structure from
a maintenance viewpoint

Equipment

Spare part

Assembly

Assembly
.....

Assembly

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Spare part

Spare part

Spare part
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Bills of materials (BOMs)

Mapping to maintenance objects

Equipment 123

Equipment
BOM

Funct. location 1-XX

Funct. location
BOM

Equipment 123
Equipment 133

Material 3711

Material
BOM

Equipment 312
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Classifying PM
Objectives:

Additional technical information on objects

Grupping of objects (functional locations,
equipment, material etc.)

Searching for objects

Analyses of objects

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Measuring point / Counter

Definition

Measuring point
Physical or logical place, defined in connection with a piece of equipment, at which a
condition is defined

Counters
The means used to express the usage of an object, the consumption or depletion of a
resource

Measurement record
Record that contain the measurements and counter values of measuring points and
counters

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Work centers
Work center

Description of the person responsible

for the work center
Location
Usage plan (only for PM task list)

Basic data

Suggested values

Control keys
Pattern keys (to describe operations)

Capacity data

Capacity type (person/maschine)

Capacity (BEB presently, pool capacity)

Allocation data

Cost center
Activity type

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Maintenance Processing

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Overview PM
Techn. object

Functional flow

Direct creation
of an order

Notification

Maintenance plan

PM Order
Planning /
Release / Print
technical
completion
confirmation

Completion
confirmation

Order processing
Material own / external
Activity own / external

Completion / settlement
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Techn.
objekt

History
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Notification

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PM Notification
Notification types

Malfunction Report
Describes the condition of an object,
especially a malfunction
Activity Report
Describes an already-completed PM activity.
This is a purely technical documentation
Maintenance Request
Requests a maintenance activity or measure
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PM Notification
Design of a PM notification
Description (long text)
date/time/reported by
Notification
PM objekt:
Funct.Location
Equipment
Assembly
Notification
items

Actions
Tasks

Location of damage
Damage
Cause of damage
Activity
Auzsfhrungsfaktoren
Schedule
Task description

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PM Notifications
PM Catalog

Catalogs
Cause of damage
Damage
Activity

Catalog example

Setup of a catalog

damage
catalog: C
ALLG (gen. Code
Damages)
1000 Break

catalog
code
group

code
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1100 Fire
1200 Corrosion
1300 Erosion
1400 Cavities
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Maintenance Orders

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PM Order
Functional Flow
Maintenence
plan

PM Notification
Material planning

creation

Capacity planning

release

Purchase
execution
Materials management
Completion confirmation
Internal
cost allocation
Completion
Order settlement
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PM Order
Creation of a PM Order
Creation of an order
based on a
notification

Automatic
generation of a PM
order from
maintenance
item

Collection of
PM notifications
into a PM order

PM Notification

Maintenance
item

PM Notification

PM Order

PM Order

PM Order

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Direct order
creation

PM Order

PM Order
Allocation

Functional location/
Equipment
Default Rule

Order
Accounting data
Cost center
Attachment

Special tasks can call for

a change in the allocation
rules !

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Task Lists

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Task List Usage

Types

Usage

- Equipment-specific
task lists

- Recurrent activities
- Standardisation of work processes

- PM instructions
(equipment-neutral)

- Plan maintenance steps effectively

- Assignment in maintenance plans
- Process PM orders in a timely manner

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Task List Structure

Task list header

Work item

Equipment
Planner group/
Planner group counter
Maintenance strategy
Internal activity
Default values
Work center involved
Control data
External activity Directory of services
Supplier
Delivery time
Purchase data

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Maintenance Planning

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Maintenance Planning
Definition of a Maintenance Strategy
Strategies contain general scheduling rules
for preventive PM tasks, which can be assigned to
several maintenance plans .
In order to map the different maintenance intervals a
so-called maintenance package is assigned to a
strategy.

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Maintenance Planning
Maintenance Plan types
 time-dependent maintenance plan
 based on a maintenance strategy
 due to time intervals
 activity-dependent maintenance plan
 based on a maintenance strategy
 due to time intervals

 Multiple counter plan

 no maintenance strategy
 Cycles are defined in the maintenance plan
and if needed they are mapped to counters
 Cycles can be combined with:
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earliest occurrence
 AND: at the latest occurrence

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Maintenance Planning
Elemente der Wartungsplanung
Maintenance strategy
Maintenance strategy

Maintenance plan

Maintenance order

Maint. scheduling plan

Maint. packages
time-dependent
activity-dependent

Maint.
items

Maint.
orders
Objects
Functional locations
Equipment

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Operations
Equipment plans
PM instructions

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Analyses

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History
PM History Database

Maintenance History
Assignment history

Master records
Equipment

functional
location

Order history

Notification history

PM order
Costs
Material
Int. operations

PM notification
Damages
Causes
Activities

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History
PM History aggregation levels

Aggregate using key figures

Aggregate using dif. criteria

Individual documents

PMIS

List processing

equipment, notifications, orders..

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Contact information
 P&S Consulting GmbH








Am Kiekenbusch 10
47269 Duisburg
Frank Ostwald
Director Marketing & Sales
0203-75 99 0-29
Frank.ostwald@ps-consulting.de
www.ps-consulting.de

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