PM-

Plant
Maintenance
Module
SAP R/3
 Organizational Structures in PM
General organizational units e.g. Corporate group
Client Company code
e.g. International subsidiary
Plant e.g. Production plant
Storage location e.g. Spare parts warehouse

Location-based organizational units

Maintenance plant e.g. Plant with technical system
Location e.g. Area, buildings

Plant section e.g. Production area,

plant engineering

Planning-based organizational units

PM planning plant e.g. Plant with PM planning
PM planner group e.g. Foreman, work scheduler

PM work centers e.g. Mechanics, electronics

 Organization of Maintenance Planning

Plant 1200 Plant 1300

Maintenance Maintenance
requirement requirement

Workshops

Plant 1000 Warehouse

Planning of
Maintenance
maintenance
requirement
requirements

Workshops
Material
The following scenarios can be made in SAP

01. Notification
02. Maintenance Order
03. Maintenance Task list
04. Maintenance plan
05. Conformation/TECO of maintenance orders
06. Settlement of order
07. Spare parts Management
08. Work Permits
09. Warranty
10. Measuring point and Measuring documents
11. Calibration of instruments
 Master Data
To perform the above scenarios the following Master
data are most important in SAP R/3

01. Functional location

02. Equipment
03. Bill of Materials
04. Maintenance Work Center
05. Maintenance Task List
06. Class and Characteristics
07. Maintenance Plan/ Scheduling
08. Catalog (Object part, Damage, Cause,
Code, Task, Activity)

Cont.
 Master Data

09. Measuring point / Measurement document

10. PRT - Production Resource Tool

NOTE--only if master data is accurately maintained,

you will stand to gain by getting very useful standard
report for your effective analysis and make your working
life enjoyable.!!!
Work Center
 Work Center

Definition
 The
 The work
work center
center is
is an
an organizational
organizational unit
unit that
that contains
contains

group
group of
of resources
resources who
who can
can perform
perform work
work

 ItIt specifies
specifies where
where and
and by
by whom
whom the
the operations
operations can
can be
be
performed.
performed. Machines,
Machines, people,
people, groups
groups ofof people
people and
and so
so
on,
on, can
can be
be defined
defined as
as work
work centers.
centers.
Functional Location
 Functional Locations

The functional location is an organizational unit,

that structures the maintenance objects of a
company according to three types
1. Functional
2. Process-related
3. Spatial criteria .
A functional location represents the place at
which a maintenance task is to be performed.

A functional location represents system area at

which an object can be installed. The objects that
can be installed at functional locations are called
equipment in the SAP R/3 System
 Functional Locations

Multi-level hierarchies Structure technical systems

based on

spatial

technical

functional

Criteria
 Example of a FL Structure
C1
Clarification plant
C1-M C1-B
Mechanical Biological
purification purification

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

Oil/fat Pump Filter
Sand trap trap plant station

C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3 C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2
Sand Fat Filter
Reservoir Ventilator dredger Reservoir Ventilator dredger Pump 1 Pump 2 Ventilator cell

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

Filtrate
Valve 1 Valve 2 Inlet level Outlet

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

Valve 1 Valve 2 Valve 1 Valve 2
 Structure Indicator

Edit mask AN-ANN-N-X-X

A = Alpha
N = Numeric
X = Alphanumeric
Hierarchy levels 1 2 3 4 56

Location number A1 System

A1-B Area
A1-B02 Sub-area
A1-B02- 9
Function
A1-B02- 9-C
Sub-function
A1-B02- 9-C- 1
Item
Equipment
 Equipment

Individual, physical object that is to be maintained as

an autonomous unit. Equipment can be installed and
dismantled at functional locations.
•Perform individual maintenance tasks for the
equipment
•Keep a record of the maintenance tasks performed for
the equipment
•Collect and evaluate data over a long period of time
for the equipment
•The costs of maintenance tasks can be monitored for
the Equipment
 Installation/Dismantling of Equipment

Functional location

Equipment
History of Document Changes
which SAP tracks

Documents
Classification
Measuring point
Long text
Installation location
Permits
Addresses
Bill of Material - BOM
Components (Spare Parts) / Bill of Materials

A maintenance bill of material (BOM) is a complete,

structured list of the components making up a
Equipment. The list contains the quantity and unit
of measure of the components. The components
can be stock or non-stock spares .
 Bill of Material Categories

Material master record Material BOM

Material

Equipment master Equipment BOM

record

Functional location Functional

location BOM
master record
Material Master
 Type of Materials

ROH - Raw Materials

HALB - Semi finished Products

FERT - Finished Product

ERSA - Spare Parts

HIBE - Operating Supplies

Maintenance Assembly
For Plant Maintenance
Initial screen 1

1.Part no
2. Industry Sector
3. Material Type
Initial screen 2

1.Plant
2. Storage Location
Measuring Points and
Counters
Measuring Points and Counters

Operating hrs 30
40
50
60
01275 20
10 70
80

Pressure
Temperature
2 3 51
Kilometers
 Entering Measurement and Counter Readings

30 40 50
20 60
01 275 10 70
80

2 351 Meas. Doc.

Meas. Doc.
Meas. Doc. Kilometers
Temperature
Meas. Doc. 2351
60 °C Operating
hours 01275
Pressure
58 Pascal
PRT (Production Resource
Tools)
 PRT (Production Resource
Tools)

To perform Planned/ Breakdown Maintenance works,

some resources are required. These resources are
given the term production resources/tools (abbreviated
to PRT ) in SAP.

PRT can be Equipment, Documents and Materials.

Eg: Welding Machine, Megger

 Class and characteristics

Functional Locations and Equipment can both be further

detailed using Classifications functionality.

Classifications are split into two separate functions:

Class - Grouping of data items such as functional

location, equipment etc - Ex : Computer , Valves,
Pressure gauge
- Class specific characteristics can be assigned

Characteristics - Describes the attributes of the

technical object
 NOTIFICATION

• Notification is a intimation to start a

maintenance activity
• For Breakdown maintenance business
process Notification is mandatory
• Notification does’nt have link with Material
or Finance.
 Notification Type

M1 - Maintenance request

To carry general Maintenance activity

M2 - Malfunction report

To carry maintenance for Malfunction

Notification which is affecting business.

type
M3 - Activity report

Carried to recored a activity that is

Completed
 PRIORITY
Thork Order has a Priority field that indicates the urgency of the work.
The Work Order has a Priority field that indicates the urgency of
the work and updates date accordingly.
The periodization has to be done in the notification before
creating the Work Order. A change later on in the Work Order
will not change the Dates in notification
The following priorities are defined as GAME work order
priorities:
Routine Work Level 1 2 Weeks – 4 Weeks
Routine Work Level 2 4 Weeks – 6 Weeks
Routine Work Level 3 6 Weeks – 10 Weeks
Relevant
Routine Work Level 4 8 Weeks – 14 Weeks start
Priorities
and unit
1
–The phas to be done in the 2
. Relevant
.
. end
and unit
 Field Selection for Notifications: Influences

Activity category

Create PM Notification: Malfunction Report

Notification type
Notification 100123 M2
Status MOFN
Order
Origin indicator Notification

Items

Catalog profile
Fields are controlled
using
Field selection
Priority

Application
component
 Catalogs

Catalog types Code groups Codes

Tasks Electrical work Replace cable

Causes of damage Mechanical tasks Replace fuse
Activities . Replace starter
.
Object parts .
Damage

Selection sets of
Codes
Mandatory evaluation
Administrative data
 Assigning Catalogs to Notification Types

Notification type M2 Catalogs

2

Problems: C
Causes: 5 5
Tasks: 2
Activities: A
Object parts: B

C
 Assigning Catalog Profiles to
Notification Types
Maintenance
Notification

Notification
Notification type
type
Catalog profile

PM catalog type Code group

Damage 001 1000

002 5400
Task M*
Object part GEN
 MAINTENACE ORDER

• Maintenance order is also called work order

process which is the different maintenance
business process/flow carried by business.
 Order Category, Order Type

Order type
type

PM01 – Preventive Maintenance order

PM02 - Breakdown maintenance order

PM03 – Corrective maintenance order

PM04 – Calibration order

PM05 – Refurbishment order

 Business process in PM
CORRECTIVE MAINTENANCE
a not This maintenance is a not a planned maintenance can be done at any required time when
there is a corrective maintenance activity required.aintenancanbe done at any required time when

PREEVNTIVE MAINTENANCE
This is carried as preplanned maintenance to avoid breakdown.eakd

BREAKDOWN PROCESS
This maintenance is carried when a breakdown had happened and business loss involved

is CALIBRATION PROCESS
The objective of a calibration inspection is to determine whether each piece of
equipment specified in the maintenance order meets the predefined performance specification

REFURBSIHMENT PROCESS
The process of repairing spare parts and returning the spare parts to the warehouse or to
the equipment. You can define a Refurbishment order as Maintenance order by which you can
execute the process of refurbishing damaged equipment.

process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You
 GENERAL MAINTENANCE
a not This maintenance is a not a planned maintenance can be done at any required

time as a unplanned routine maintenance

ntenancanoat any required time when

.

process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You
can define a Refurbishment order as Maintenance order by which you can execute the process of
refurbishing damaged equipment
 CORRECTIVE MAINTENANCE
a not This maintenance is a not a planned maintenance can be done at any required

time when there is a corrective maintenance activity required To solve the

issueintenancanoat any required time when
.

process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You
can define a Refurbishment order as Maintenance order by which you can execute the process of
refurbishing damaged equipment
 BREAKDOWN MAINTENANCE
a not brThis break down maintenance is a not a planned maintenance can be done at

when business process disturbed or production loss involved.

with
.
Notification
process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You
can define a Refurbishment order as Maintenance order by which you can execute the process of
refurbishing damaged equipment
 Calibration
Maintenance Plan-Based Test Equipment Management
----1----2----3----4----5

ve ry 78
te rval : E
ecti on in
Insp
s
w eek
Characteristics:
 Cutting length: 10.087 0.01
 Diameter of probe pin: 2.9 0.03
 Measuring edge Sharp

How do I organize the 


Quantitative
Qualitative
maintenance of my test
equipment?
 PM
Calibration
Order
Calibration inspection
created
Maintenance
Equipment
Plan
Master

Inspection lot created

Equipment
Task List

Calibration
Inspection

Result recording
Notification
Defects recording

Usage Decision

Calibration
History in
SAP
 REFURBISHMENT PROCESS
a not Refurbishment of repairable spares is widely used in process industry, oil
producing and processing, steel processing. It is very important to make
repairable spares a high level system availability in plant maintenance.These
repairable spares of above industory are often the core process in industry
process and have high value. So it is more cost-effective to do refurbishment
than a brand new purchase.

with
.

process of repairing spare parts and returning the spare parts to the warehouse or to the equipment. You
can define a Refurbishment order as Maintenance order by which you can execute the process of
refurbishing damaged equipment
PREVENTIVE MAINTENANCE
Task List
 Task List

Maintenance task lists describe a sequence of individual

maintenance activities which must be performed repeatedly.
There are three types of maintenance task lists that can be
distinguished from one another :
• Equipment Task List
• Functional Location Task List
• General Maintenance Task List
The most important elements are:
•Operations (activities)
•Sub-operations (Sub-activities)
•Material (Components) for individual activities
•Maintenance Packages
•No. of persons & Time
•Production Resources/Tools
Maintenance Task List Types

E Equipment task list

G General maintenance task list

F Functional location task list

 Maintenance Task Lists: Number Assignment

K1-M01 Task list group Counter

Functional 742 01
location
02

03

Internal number Pump_Wtg Task list group Counter

assignment
Pump_Wtg 01
200125 Task list group Counter
Equipment 395 01 02

02 03

03 04

04 Internal and external

Number assignment
Internal number
assignment
Maintenance Plan
 Maintenance Plan: Functions

Orders/
Service Notifications
Inspection Lot
entry sheets
Order 901762
Order 901761
Maintenance plan Order 901760 Service
Service entry
entry sheet
sheet Notificat
Notificat
01 Electrical work ionion
Notificat
ion
Scheduling data 02 Sanitation work

Maintenance item

Call date

Cycle start Cycle

 Overview: Maintenance Plans

Maintenance plan

1 Single cycle plan Strategy plan Multiple counter plan

Time-based Performance-based
 Single Cycle Maintenance Plan

Interval (cycle)

Maintenance plan
3 months

Scheduling data

Maintenance item

Maintenance item

Reference object

Task list
Responsibilities /
Planning data
 Maintenance Plan with Task List

Maintenance plan

Task list
Scheduling data

0010 Switch off

Maintenance item
0020 Safety check
0030 External visual check
0040 Exchange special seal
0050 Fit casing H9
0060 Check ring Z7
 Scheduling Functions - Single Cycle Plan

Cycle start
Start
New
Cycle start

Manual Restart
call

Start date Schedule

Last
a ctual
date
 Deadline Monitoring

Order 901760
Orders for the
next 90 days
Order
Dead
line
Mon
itorin
g
Order

15.03.2000 15.06.2000 15.09.2000 15.12.2000

= Planned dates

Day of = Scheduling period

execution
Maintenance Planning with Strategy

1 mon
th

External visual inspection

3 mon
ths

Internal visual inspection

1 year

Check gear teeth for wear

Which parts must be

maintained at what
intervals?
 Maintenance Strategy

1997

Scheduling indicator Package definitio

Time - using key date
Strategy
6m
on
ths

3m 3m 12
on mo
ths on nth
ths s
 Maintenance Package

Package number
Description

3 mon Cycle length

t hs

Unit of
measurement
Hierarchy
Offset
Preliminary /
follow-up buffer
 Task List and Maintenance Strategy

Task list Strategy 6m

on
th s

3m 3m 3m
on on on
ths ths ths

0010 Switch off

0020 Safety check

0030 External visual check

3 mon
0040 Exchange special seal ths
0050 Fit casing H9

0060 Check ring Z7

6 mon
ths
 Multiple Counter Plan

Flying hours
00015600

Number of take-offs / landings

00001995
The engine should be
changed after 18,000
flying hours or after
12,000 take-offs...and
landings.
 Preventive Maintenance: Phases and Roles

Phase Contents Roles

1 Task list
Create task lists for different
objects
Maintenance
planner

2 Maintenance Create maintenance plans

Maintenance
plan planner

Maintenance
3 Schedule Schedule maintenance plans
planner

Maintenance Maintenance
4 Process maintenance orders
technician
order

Technical Technically complete Maintenance

5 maintenance orders supervisor
completion
 Maintenance Activity Types

PM order types PM activity types

- PM01 - Inspection
- Maintenance
- PM02 - Repair - Function for grouping
the actual costs in the
- Revision object history
- Cleaning
- Warranty
- Insurance
...
 Permits

 Technical permits
(unclassified)

Order

0010
0020
 Technical Permits

Technical Permit
object A001 Boiler usage permit
1 Assignment A002 Welding permit
A002 Welding permit A003 Safety check

Order Permit
A002
A002 Welding permit 3 must be
issued

Create order
>> 10 Renew weld Release ?
2 Permit is 20 Check electrics

copied
 Print Control

Print proposal
Selection
for each
Define shop papers document type
•Program

General / user-specific
print specifications
Printing Notifications and Orders

 Printing orders and

notifications together
 Using the same forms
 Revising shop papers
 Printing Orders

Order
X
Change order

t d i re ctly
Prin

Select shop papers

Shop paps. Description Output device Print diversion
0010
0020 2010 Op. Control ticket A000

2020 Job ticket A000

2030 Pick list A000
2040 Time ticket A000
 Historical Maintenance Orders
Data transfer
Direct
entry

Order history

Historical maintenance order

Object list Equipment / Funct. location

Equipment Operations
Internal/external
Equipment Material components
Functional loc. Costs by valuation category

Completed Notifications
Equipment /
functional location
 Actual Costs for the Order

Order execution

Order
870986

Costing

• Time confirmations
Actual costs • Material withdrawals
• Goods receipts
 Detailed Cost Analysis with CO Report

Analyze Cost Results: Order

Order 902263
Values in US $
Cost elements Plan Actual Plan quantity Actual quantity
* 400000 Consumption of raw materials 18.00 7.58 9 PC 3 PC
* 403000 Use of operating supplies . . 45.00 45.00 1 PC 1 PC
* 615000 Direct internal activity . . 488.56 199.36 5H 2H
** Debit 511.56 251.94 X X
4100 Technical service 251.94 - 2H-
* 650000 Order settlement 251.94 - 2H-
** Settlement 251.94 - 2H-

*** Balance 511.56 X X

 Options for Order Completion

Plant Controlling
Maintenance

confirmation
 Completion

 (Business)
completion

 Settlement

completion
 Technical
 Execution
 Planning

 Release

Order
Time

• Order not modifiable • Postings cannot

• Postings can be made to order
be made to the
order
 Warranty Types

Vendor
warranty

Manufacturer
warranty
Warranty
 Structure of Master Warranty

Warranty type
Warranty Description
header Classification

Warranty
Service activities
items inclusive/exclusive

Warranty
counter Counters, limits
 Important Transaction codes

01 Functional Location Master IL01

02 Equipment Master IE01
03 Material Master MM01
04 Bill of Material (FL) IB11
05 Bill of Material (Equipment) IB01
06 Bill of Material (Mateerials) CS01
07 Work Center IR01
 Important Transaction codes

08 Material Where used List CS15

09 Task list IA01
10 Maintenance plan IP01
11 Maintenance Schedule IP10
12 Dead line Monitoring IP30
13 Catalog QS41
14 Measuring point IK01
 Important Transaction codes
15 Measuring Document IK11
16 PRT - Equipment IE25
17 Notification Creation IW21
18 Maintenance order Creation IW31
19 MTTR & MTBF for FL MCJC
20 MTTR & MTBF for Equipment MCJB
Thank you
Contact
Rupesh SAP PM Senior consultant
+ 91 866 08 169 19