EAM-Plant Maintenance Solution For Paper Industry - Final - V1.1 - C PDF

APER (SAP COE)
Gupta & Gaurav S
January 2013
A Glimpse of SAP S4HANA EAM-Plant

Maintenance Solution in Paper Manufacturing
Industry
Contents
1 Purpose .................................................................................................................................... 5
2 Background .............................................................................................................................. 5
3 Overview of Industry Process &Types of Assets ....................................................................... 6
3.1 General Overview .............................................................................................................. 6

3.2 Different types of Paper usage ........................................................................................... 8
3.3 Known Paper Industries ..................................................................................................... 8
3.4 Pulping............................................................................................................................... 9
3.5 Paper Making................................................................................................................... 10
3.6 Key Assets in paper manufacturing .................................................................................. 11
3.6.1 Pulp Assets ............................................................................................................... 11
3.6.2 Mill Wide Support Systems ....................................................................................... 13
3.6.3 Paper Machines ........................................................................................................ 13
3.6.4 Converting Lines ....................................................................................................... 14
3.6.5 Utilities ...................................................................................................................... 15
4 Importance of Modelling Technical Assets and S4HANA Maintenance Processes in EAM ..... 15
5 Typical Maintenance Organizational Structure ........................................................................ 17
5.1 Maintenance Teams/Work-Centers.................................................................................. 18

6 Modelling Master Data in S4 HANA ........................................................................................ 18
6.1 Functional Location and Equipment ................................................................................. 19

6.1.1 Naming Convention .................................................................................................. 20
6.1.1.1 Pulp and Paper ..................................................................................................... 22
6.1.1.2 Paper Machine ...................................................................................................... 25
6.1.1.3 Converting Lines ................................................................................................... 27
6.1.1.4 Buildings and Utilities ............................................................................................ 30
6.1.1.5 Mill wide Systems and Equipment’s....................................................................... 30
6.1.1.6 General Attributes of Technical Systems ............................................................... 31
6.1.1.7 Technical Object Types ......................................................................................... 32
6.1.1.8 Bill of Materials ...................................................................................................... 33
6.2 Measuring Points ............................................................................................................. 34
6.2.1 Measuring Points ...................................................................................................... 34
A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 2

This document is for internal knowledge sharing purpose only.
6.2.1.1 Measuring Points – Boiler system (Utilities) ........................................................... 34
6.2.1.2 Measuring Points – Other Assets .......................................................................... 34
6.2.1.3 Measuring Points – Paper Machine ....................................................................... 35
6.2.1.4 Measuring Points – Converting (Tissue) ................................................................ 36
6.2.1.5 Measuring Points – Drying .................................................................................... 36
6.2.1.6 Measuring Points – Pulping section ....................................................................... 37
6.2.1.7 Measuring Points – Entry List ................................................................................ 39
6.3 Task-Lists ........................................................................................................................ 41
6.4 Maintenance Plans .......................................................................................................... 42
6.5 Catalogs and Code Groups.............................................................................................. 43
7 Principles of Reliability and Centralized master data ............................................................... 45
7.1 Centralized Master data ................................................................................................... 45

7.1.1 Centralized Task lists ................................................................................................ 45
7.1.1 Centralized Bill of Material ........................................................................................ 47
7.1.2 Centralized Maintenance Plans ................................................................................ 50
7.1.3 Centralized Reference Equipment ............................................................................ 51
7.2 Measuring Points for Condition Based Maintenance ........................................................ 52
7.3 Managing Reliability based Maintenance using custom solution ...................................... 53
8 Business Roles Involved ......................................................................................................... 57
9 General Process Overview ..................................................................................................... 57
9.1 Key Custom Functionalities used/Built ............................................................................. 59

9.1.1 Notification initiation and approval using custom FIORI App ..................................... 61
9.1.2 Notification phases ................................................................................................... 62
9.1.3 Work Order planning using custom FIORI App ......................................................... 63
9.1.3 Work Order Budgeting and Approval ........................................................................ 64
9.1.5 Work Order Scheduling ............................................................................................. 65
9.1.6 Execution using custom FIORI App .......................................................................... 67
9.1.7 Work Order Phases .................................................................................................. 69
9.2 Specific Functionality to use 3D VE ................................................................................. 69
9.3 Key Integration areas ....................................................................................................... 71
10 Key KPI’s............................................................................................................................. 72
11 Interfaces ............................................................................................................................ 76

12 Key Transactional Metrics ................................................................................................... 76
13 General Industry Technical Terms(Source as in section 14) ................................................ 77
14 Appendix for Source of Reference Information .................................................................... 78
Version History
Document Version Owner/Approver Date(DD/MM/YYYY)
Initial Draft 0.1 Gaurav Bhatia 13/03/2020
Reviewed 0.2 Carlos Gonzalez 21/03/2020
Updates based on 0.3 Gaurav Bhatia 30/03/2020
Review
Final Approval 1.0 Carlos Gonzalez 02/04/2020
Approved to Publish 1.1 William Chadrow 10/04/2020

1 Purpose
Asset intensive industries such as Process, Industrial products manufacturing are made up of complex
mechanical and electrical systems and there are hundreds of thousands of moving parts. Paper production
involves lots of sensitive equipment such as scanners and drives as well. If a production line is to be reliable,
the equipment must be kept in good working order and regular maintenance is an essential ingredient to achieve
this. An industry will not survive for long as a viable operation if it is allowed to deteriorate because of lack of
maintenance. These industries operate on a platform where safety and statutory compliance are of utmost
importance in day to day work. Such organizations operate on a tightly integrated model where operations and
maintenance along with logistics collaborate to maintain the sustainability and the desired reliability of their
systems.
These organizations utilize ERP systems which facilitate to manage the day to day maintenance work which
helps minimize the overall turnaround time thus maximizing the overall equipment efficiency.
Master Data and transaction data builds an ecosystem with accurate key elements which are further used in
extracting data for analysis and reporting. Inaccurate design leaves many pitfalls which can have adverse
effects on the overall business operations. It is imperative for functional consultants to gain an understanding
of the typical assets and their modelling concept with a basic maintenance process overview.
This document is prepared to summarize the basic modelled assets and a high-level process in S4 HANA EAM-
Plant Maintenance module based on a typical project scenario in a paper products manufacturing industry. The
objective is to:
• Provide a high-level understanding to EAM-Plant Maintenance Functional Consultants and

• Use it as a support document for gathering any information to support future
RFP/Demonstrations/Implementations.
2 Background
Reliability, Availability and Maintainability are the key process indicators which drive the overall health of the
technical system. A production process will not survive for long as a viable operation if it would deteriorate
because of lack of maintenance. It is imperative for any such organisation to have good ERP software support
structure which can supplement the effectiveness of day to day operations thus managing its sustainability and
reliability and achieve the optimum equipment efficiency.
This document typically highlights the general assets and their modelling as technical assets in S4 HANA from
EAM-plant maintenance perspective and the high-level process matrix which helps to support the daily

operations and maintenance business processes. This document is solely prepared based on exposure to
functionalities on a project in similar industry.
Note: Design rules should not be interpreted as a standard for similar industry as it may vary based on an
individual organization. S4 HANA screens highlighted have been modified in some cases to remove any client
specific information wherever possible. Images wherever necessary for illustration have been provided with
links to the relevant website. It is advised to open the link by pasting to the browser separately in case the click
action does not work.
Note: This document is for internal knowledge sharing purpose only.
3 Overview of Industry Process &Types of Assets
3.1 General Overview

The pulp and paper industry comprises of companies that use wood as raw material and produce pulp, paper,
paperboard and other cellulose-based products.
Paper and Pulp is expected to grow at a CAGR of roughly 4.7% over the next five years, will reach 79600
million US$ in 2024, from 63300 million US$ in 2019, according to a new study(Source:
https://www.marketwatch.com/press-release/paper-and-pulp-market-2019---global-industry-research-
update-future-scope-size-estimation-revenue-pricing-trends-growth-opportunity-regional-outlook-and-
forecast-to-2024-2019-09-13)
A snapshot of the demand for paper and pulp products based on a study by McKinsey is highlighted below:
Figure 1 Market demand study

https://www.mckinsey.com/industries/paper-forest-products-and-packaging/our-insights/pulp-paper-and-
packaging-in-the-next-decade-transformational-change
The figure below highlights a very high-level process of paper making for basic understanding purpose only.
The actual process is more complex and intensive.
Table 1 High level process overview
Below link can be referred for more understanding of the detailed process:
http://www.brdisolutions.com/wp-content/uploads/papermaking.jpg
Figure 2 Some Facts

3.2 Different types of Paper usage
The different paper-based products can be classified as:
Graphic E.g. Newsprint and Writing
Packaging E.g. Carton Board and Container Board
Others E.g. Tissue
The figure below displays (not limited to) the different uses of paper in day to day life:
Figure 3 Uses
3.3 Known Paper Industries

Some of the known paper related industries are as below:
Figure 4 Known Paper industries
Source:(https://www.pulpandpaper-technology.com/articles/top-largest-paper-producing-companies-in-the-world)

The below sub-sections provide a high-level knowhow of two important sections i.e. Pulp and Paper section.
3.4 Pulping
Pulp is a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulose fibers
from wood, fiber crops, waste paper, or rags. Many kinds of paper are made from wood with nothing else
mixed into them. This includes newspapers, magazines etc. Pulp is one of the most abundant raw materials.
The pulping process uses sulfur compounds to break wood down into pulp. There are several different
processes which can be used to separate the wood fiber. Some of these sulfur compounds escape
the process and are released into the atmosphere. Sulfur compounds, such as hydrogen sulfide, dimethyl
sulfide, and dimethyl disulfide, are famous for their pungent odor and very low odor thresholds
There are two main types of pulping process to produce virgin fiber and two intermediate methods. These are
mechanical (or groundwood), chemical, thermo-mechanical (TMP) and chemical thermo-mechanical (CTMP or
semi-chemical).
• Mechanical Pulping:
This is the quickest, least costly method of obtaining virgin fibers. The wood chips are washed, to remove any
soil, stones or other contaminants, and mechanically ground.
Use:
Mechanical pulp is used for low grade papers such as newsprint and for blending with chemical and semi-
chemical produced pulps to reduce costs.
Figure 5 Basic pulping process
• Chemical pulping:
Here the wood chips are placed in a digester where the cellulose fibers are separated from the lignin and other
impurities using heat and chemicals. If white fibers are required, bleaching is carried out at this stage. This is
the most expensive method of producing fibers for paper and paperboard manufacture, due to the lower yield
compared to mechanical pulp and the heat energy and chemicals required.
Use:
Chemical pulp is also used where maximum toughness, whiteness and purity are required. Examples are the
outside plies of folding boxboard, cartons for high value cosmetics and liquid packaging form fill seal cartons.
Paper made from chemical pulp is often referred to as ‘wood free’.
Below image displays a typical pulp and fiber combination:(Refer image 1 only on the below webpage)
http://www.paperpulpingmachine.com/applications/wood-pulp-making/eucalyptus-pulp-making/

3.5 Paper Making
The paper machine is the heart of paper manufacturing. Modern paper-making machines are based on the
principles of the Fourdrinier Machine, which uses a moving woven mesh to create a continuous paper web by
filtering out the fibers held in a paper stock and producing a continuously moving wet mat of fiber. This is dried
in the machine to produce a strong paper web. The paper machine is sub divided in to the following sections
broadly:
• Wet section/Forming Section

- The forming section makes the pulp into the basis of for sheets along the wire
• Wet Press Section
- The press section, which removes much of the remaining water via a system of nips formed by rolls
pressing against each other aided by press felts that support the sheet and absorb the pressed
water
• Dryer Section
- dries the paper by way of a series of internally steam-heated cylinders that evaporate the moisture
• Calendar Section
- used to make the paper surface extra smooth and glossy
• Reel Section
- The paper is wound onto metal spools using a large cylinder called a reel drum
• Winder Section
- In the winder section reels of paper are slit into smaller rolls of a width and roll diameter range
specified by a customer order
Refer links below for images of a paper machine:
https://en.wikipedia.org/wiki/Paper_machine#/media/File:Fourdrinier_paper_machine,_Frogmore_Mills_-
_geograph.org.uk_-_1544694.jpg
https://en.wikipedia.org/wiki/Paper_machine#/media/File:Fourdrinier.svg

3.6 Key Assets in paper manufacturing
The key assets (not limited to) that support processes within a Paper industry are:
 Pulp Processing Machines/units
 Paper Machines
 Converting Machines
 Plant and Machinery/Other support Equipment’s
Paper Industry
Facilities Control System Plant &Machinery

Pulp and Paper
- Buildings -SCADA -Tools
Processing Units Paper Manufacturing Packaging
Figure 6 Key asset types
The details of key assets are explained under sub-sections below.
3.6.1 Pulp Assets
Pulping systems - Serve to prepare the raw material for paper making.
The main components of the pulping system are:
• Pulper comprising of Agitators, Conveyors, Exhaust Fans, Lube Oil System
• Chemical Additive system comprising of Dye storage tanks, Broke Screening, Coarse Screening
• Fiber Recovery systems
• Fine screening
• Stock Storage systems such as Stock Chest
• Sump water system including Effluent storage

The images below represent some of the components of a pulp unit which can be displayed using the below
links:
Wood Chips
Wood Chips (Raw
Material)
https://www.alamy.com/a-bulldozer-moving-wood-chips-used-for-making-paper-at-lewiston-idaho-
image3344017.html
Pulper
https://www.google.com/search?q=paper+pulper+machine&rlz=1C1GCEB_enIN836IN836&sxsrf=AC
YBGNSIeoBLt9TXlVrgfAbIsIwiZ_zmmQ:1574751273129&source=lnms&tbm=isch&sa=X&ved=2ahU
KEwjD_PnRpYfmAhUzyzgGHe6dBXYQ_AUoAnoECAwQBA&biw=1395&bih=624#imgrc=6pteyy_FZ
WD_9M:
https://www.google.com/search?rlz=1C1GCEB_enIN836IN836&tbm=isch&q=digesters+in+paper+ma
nufacturing&chips=q:digesters+in+paper+manufacturing,online_chips:continuous+digester,online_chi
ps:kraft+pulp+mill&usg=AI4_-kS8KlHz_aJ575v4ulmLiAZNZw75-
A&sa=X&ved=0ahUKEwiItZXsla3mAhVO6nMBHXVhBSUQ4lYILCgA&biw=1402&bih=619&dpr=1.35
#imgrc=sac-gGPpSEOljM:
Pressure Screen
https://www.google.com/search?rlz=1C1GCEB_enIN836IN836&biw=1395&bih=624&tbm=isch&sxsrf
=ACYBGNQfZQ3wbsnthF424pYJ4lbBTqbwbQ%3A1574751704023&sa=1&ei=2M3cXcqGAYTfrQHF
_qqgBA&q=broke+screening+in+paper+industry&oq=broke+screening+in+paper+industry&gs_l=img.
3...35964.42522..42805...1.0..0.540.7524.3-11j6j2......0....1..gws-wiz-
img.......35i39.rq9n601KHZw&ved=0ahUKEwjK0rWfp4fmAhWEbysKHUW_CkQQ4dUDCAc&uact=5#i
mgdii=t-lVa21divYEKM:&imgrc=2P_k3pRmj3wmOM:
Stock Chest
Stock chest
http://www.wfidol.tech/wap/productshow.asp?zid=26&cid=57&id=0
Conveyor
ConveyorSystems
systems
https://www.valmet.com/pulp/wood-handling/conveyor-systems/

3.6.2 Mill Wide Support Systems
These systems act as support and protection systems for smooth functioning of the overall production and
converting process:
Some important functions are as below:
• Fire protection systems
• IT systems
• General Equipment
• Material handling systems such as Baler systems (are devices that have been designed to compress
materials into a bale for storage, transport or handling)
Baler
https://www.cardboardbalers.org/what-is-a-baler-machine/
Fire Protection
https://www.quora.com/What-is-the-purpose-of-a-fire-pump-set
3.6.3 Paper Machines
The paper machine is the heart of paper manufacturing. Modern paper-making machines are based on the
principles of the Fourdrinier Machine, which uses a moving woven mesh to create a continuous paper web by
filtering out the fibers held in a paper stock and producing a continuously moving wet mat of fiber. This is dried
in the machine to produce a strong paper web.
Paper Machine
https://en.wikipedia.org/wiki/Paper_machine#/media/File:Fourdrinier_paper_machine,_Frogmore_
Mills_-_geograph.org.uk_-_1544694.jpg

3.6.4 Converting Lines
The term “Paper Converting” comes from the fact that you are taking the paper and converting it into another
product i.e. Transforming or “converting” these large parent rolls into smaller sizes.
The first and most common is cutting the paper using a paper converting machine called a Slitter / Rewinder.
This machine takes large rolls and unwinds the material through a series of blades that slit or cut the paper into
smaller widths then rewinds the paper into new rolls. The second type of converting machine cuts the entire
roll into smaller rolls without unwinding or rewinding the paper. This piece of paper converting equipment is
called a precision paper roll saw. The new resized rolls are now ready to be used in the various printing
processes required to make our everyday items like books, boxes, bags and more.
A typical example of converting section would be as below:
Figure 7 Converting Line
Some of the key sections of a converting unit are as below:
• Core Machine with Winder, Unwinder, Hopper, Log saw and Printer section
• Case packer and sealer machines
Below links can be referred to access the images of some key components of a converting unit:
Converting Machines
https://www.pulpandpaper-technology.com/products/omet-srl/as-line-tissue-converting-line-for-
paper-towels
Slitter/Rewinder
https://en.wikipedia.org/wiki/Roll_slitting#/media/File:Soma_Venus_III_-_slitter_rewinder.jpg
Log Saw
https://all.biz/automatic-toilet-paper-log-saw-cutting-machine-g12731471UA

3.6.5 Utilities
Some of the key sections (not limited to) of a utility section are as below:
• Power distribution
• Water system
• Compressed air systems
4 Importance of Modelling Technical Assets and S4HANA Maintenance

Processes in EAM
The technical asset with in S4 HANA represents the systems/sub-systems or individual machines on which
maintenance activity is to be performed. A technical asset must be created in S4 HANA when:
• It is a major value asset against which work may be scheduled, costs and maintenance history recorded
and analysed (an asset may not be a physical asset, it may include software and information)
• It is a high maintenance or operational impact asset
• There are safety or statutory requirements for identifying the individual equipment
• There are operational or maintenance requirements to record statistical details
• There are configuration control requirements to be satisfied
• There are requirements to record warranty details against the equipment
• To identify total cost of ownership (life cycle costs)
• To assess condition over its service life
• To record life information for availability statistics
• To record the installation/dismantling usage time periods

More over the entire S4 HANA landscape with the new digital user experience helps add value to an
organization (not limited to) by streamlining the maintenance processes as below:
Figure 8 Some key advantages

5 Typical Maintenance Organizational Structure
A typical S4HANA organizational structure in a paper industry can be understood as below:
Table 2 Organizational Structure
• Maintenance plant- All assets related to manufacturing and its support are installed in a maintenance
plant
• Plant Sections- Major sections which are useful for analytics and reporting are structured under each
maintenance plant
• Planner Groups: Owners or groups responsible for day to day maintenance planning

5.1 Maintenance Teams/Work-Centers
The day to day maintenance work is handled by specialists in the area of mechanical, electrical,
instrumentation teams. These teams are divided into specific areas of the production processes such as
paper machines, converting lines and so on. Machine Operators themselves do small fixes and lubrications
and hence defined as maintenance Work Center.
Figure 9 Maintenance Work centers
6 Modelling Master Data in S4 HANA
The major master data objects mapped in S4HANA are:
• Functional Locations
• Equipment’s
• Measuring Points
• Task-lists
• Maintenance Plans
• Catalogs and Code Groups
• Bill of Materials
• Classes and characteristics

The major assets defined under section 3 when modelled in S4 HANA are explained in sub sections below.
6.1 Functional Location and Equipment

Within S4 HANA ,functional location and equipment records are used to represent the technical asset register.
• Functional Locations - are used to represent technical assets when these are to be grouped based on
functional, process oriented or spatial criteria E.g.
o A converting line - which represents a process line on which a maintenance activity is to be

performed,
o Pulping section - which represents a grouping of sub-systems of a technical asset on which a

maintenance activity is performed
• Equipment’s - are used to represent technical asset when
o Technical asset that is to be maintained as an autonomous unit and is installed at functional

location for a certain period and in the course of its useful life, can be installed at different
installation locations. E.g. a pump
o During the useful life, the installation and maintenance history at a location needs to be tracked
• Key asset related information such as asset classification, asset attributes, organisational & financial
responsibility data is stored against them
The Functional Locations and Equipment’s can be categorised according to usage and reporting criteria.
• Production lines or units – Paper machine, Converting line, Packaging Line etc.
• General Assets – (Buildings, HVAC, Security, etc.)
• Tools (Plant & Machinery) – Forks, Cranes
Equipment’s can have a unique number range to differentiate as per business requirement.
The concept of Functional Location labelling and its structure modelling is explained in sub sections below for
major assets defined in S4 HANA.

6.1.1 Naming Convention
The naming conventions for each S4 HANA object is defined using some applied business rules and is driven
by the concerned business stake holders. The explanation below is to create an understanding for the labelling
of Functional locations and should not be interpreted as an industry standard or thumb rule for design.
The levels of Functional Locations are generally decided based on reporting requirements. An example of
principle behind design of levels is as below:
Structure Indicator is used as a template for creating functional location ID. General concept is to create a
hierarchy which models the entire set of assets represented in a maintainable manner and portrays the exact
structure of a maintenance organisation.
Example: If the organisation is structured on a few levels where:
Level-1- Represents the organisation or Mill E.g. a Plant or the entire organisation or a Mill
Level-2- Represents the broader units or sections within the organisation E.g. Paper Machine units, Pulp
section, Utilities section
Level-3- Represents grouping of systems and sub-systems; for example: Stock prep section of a paper machine,
Dryer of a paper machine
Level-4- Represents grouping of sub-systems e.g. Drive system, Gearbox system within a Dryer
Level-5- Represents Location of movable assets within Level 4.E.g. Gearbox within a Level 4 sub system time.
Level-6- Represents the actual physical equipment which can be installed or dismantled from its parent location
Motor
The structure indicators can be used to maintain the hierarchy. E.g.
E.g. If the edit mask is XXX-XXXX-XXXX-XXXX-XXXXX-XXXXX
XXX-can represent the manufacturing facility E.g. Paper Mill-XYZ
XXXX-Represent the manufacturing or processing units e.g. PM99 representing paper machine 99 or PLPG –
Pulping section/processing plant
XXXX- Represents the sections or systems within the main production unit. E.g. PL01, PL02 as pulper systems
or STKP or PRES as stock prep section or press section
XXXX-Can represent the sub systems E.g. SFSS Stock Feed system within the stock prep section or primary
or secondary screening systems
XXXXX-Can represent a sub-sub system of the actual system. E.g. Secondary Screen Feed pump

XXXXX- Can represent the actual location of the rotary equipment within a sub-sub system E.g. secondary
screen feed pump motor
The final Functional Location ID will be represented as below:
XYZ-PM99-STKP-SC20-SSFP1-MOTOR
Figure 10 Technical Object Hierarchy Model
The details for each of the asset type after being modelled in S4 HANA is summarized in sub-sections below:

6.1.1.1 Pulp and Paper
The figures below represent a typical pulp and paper system set up in S4HANA.
The following levels are mapped in S4HANA:
Level-2: Individual Production Units or Sections of a Mill
E.g. The figure below displays the sections such as pulping or utilities Level-1
Level-2
Table 3 Example Model of Level1 and 2
Level-3: Sub-Sections or systems
E.g. The figure below displays the typical sub sections of a pulp unit
Level-3
Table 4 Example Model of Pulp Section
Level-4: Sub-Systems
E.g.: The figure below displays the sub-systems within a pulper unit such as Infeed conveyor
Level-5: Represents the location of the maintainable asset

Level-4
Level-5
Figure 11 Example Model of a Pulper unit
The links below can be used to navigate to some important images related to assets within a pulp section:
Pulper System
https://parason.com/products/pulping/hi-consistency-pulper-system/
Digester
Digester
https://www.google.com/search?rlz=1C1GCEB_enIN836IN836&biw=1401&bih=624&tbm=isch&sxsrf=A
CYBGNSfGFwbBPaiMbQReI2REWl7ZHSx8g%3A1574764180177&sa=1&ei=lP7cXe3ACsT2rQHgs66wAw&q
=Digester+in+pulp&oq=Digester+in+pulp&gs_l=img.3..0i24.69266.74474..74697...1.0..0.343.4973.2-
13j4......0....1..gws-wiz-
img.....10..35i39j0j0i67j35i362i39j0i8i30.LWzDCv76TDk&ved=0ahUKEwjt2sHc1YfmAhVEeysKHeCZCzYQ4
dUDCAc&uact=5#imgrc=T1vAJT8B_b1MwM:
Machine Chest
The mixing chest is a large, agitated tank used for mixing various types of pulp, fillers, and additives together
in a specified formula for the paper machine
https://www.google.com/search?q=machine+chest+in+paper+making&rlz=1C1GCEB_enIN836IN836&so
urce=lnms&tbm=isch&sa=X&ved=2ahUKEwj75aSr1IzmAhV463MBHd-
4AxcQ_AUoAXoECA4QAw&biw=1401&bih=618#imgrc=dR2X2bg2iKnTWM:

Stock Chests
Pulp and paper plants use stock chests with partial mixing and recirculation loops to reduce the magnitude of
consistency fluctuations in pulp production. Minimizing these fluctuations provides a smoother, more uniform
surface and significantly improves final sheet properties. This results in more first-quality tons and improved
savings and revenue.
https://www.magnetrol.com/en/industries-applications/pulp-paper-mills/mixing-machine-chests
Broke Screening
Small debris in the approach system can cause quality problems like coating streaks or other visual defects
and production problems such as web breaks downtime. Broke screening removes impurities before they can
enter the paper machine approach system.
https://www.andritz.com/products-en/group/pulp-and-paper/paper-production/stock-preparation/broke-
screening
Waste paper Processing
Pulping>Screening>Deinking and Bleaching
http://www.paperpulpingmachine.com/analyze-waste-paper-pulp-processing/
C02 Tanks
Carbon dioxide (CO2) is widely used in the paper industry today. It is used in paper machines to adjust and
stabilize pH, to buffer the papermaking system, to decrease calcium levels, or to increase dewatering, for
instance.

6.1.1.2 Paper Machine
The paper machine can be broadly divided into the following sections:
Figure 12 Major Sections of Paper Machine
Note: above representation is just for basic high level understanding only. The actual machine is more complex and intensive.
Below Link can be accessed to view the details of each section:
https://en.wikipedia.org/wiki/Paper_machine#/media/File:Fourdrinier.svg
Each of the system is mapped into S4 HANA. The below figure highlights a few sections for basic
understanding only. Level-2
Calender
Wet End
Wet Press
Reel Section
Stock Prep
Figure 13 Model Example in S4HANAA-L2
section
Each Section is then sub-divided into sub-sections and its systems’ below is a sub division of a stock prep
section:

Level-4
Level-5
Level-6
Figure 14 Model Example in S4HANA-L3-L5
Below Links can be accessed to view some of the systems modelled above:
Headbox
https://www.valmet.com/board-and-paper/board-and-paper-machines/headbox/layering-fourdrinier-
headbox/
Forming Section
https://www.cnpapermachinery.com/product-post-02/
Drying Section
https://www.bellmer.com/paper-technology/dry-end/dryer-section/
Yankee Dryer
A common term used in Drying Section is a Yankee Dryer
A Yankee dryer is a pressure vessel used in the production of tissue paper. On the Yankee dryer, the paper
goes from approximately 42–45% dryness to just over 89% dryness. (Source-Wikipedia).
https://www.tissuestory.com/2017/09/11/steel-yankee-dryer-advantages-development-and-rapid-
acceptance/
Some common tasks on dryers are:
Inspections: Metallurgical Ultrasonic Visual
Measurements: Surface contour Shell thickness Temperature
Calendar Section
https://www.bellmer.com/paper-technology/dry-end/calender//
https://newsroom.domtar.com/paper-making-101-inside-paper-making-process/

Rolls
https://www.tokuden.com/english/product/jacket/papermaking.php
Doctor Blades
Doctors are used on paper and board machines to remove excess water and contaminants from roll and
cylinder surfaces, and to remove the sheet from these surfaces during sheet breaks and threading
https://en.wikipedia.org/wiki/Rotogravure
https://www.convergencetraining.com/paper-machine-doctor-blade-components-and-troubleshooting.html
Reel
http://hyecoinnovation.com/upload/3779/o/5-11-reel-machine-01.jpg
https://www.convergencetraining.com/paper-machine-reel-systems.html
Reel Spool
http://m.maitocn.com/reel-winder-section-of-paper-machine/reel-spool.html
6.1.1.3 Converting Lines

The term “Paper Converting” comes from the fact that you are taking the paper and converting it into another
product. Transforming or “converting” these large parent rolls into smaller sizes.
The new resized rolls are now ready to be used in the various printing processes required to make our
everyday items like books, boxes, bags and more.
As an example - By “tissue and paper converting machinery” we call all the range of paper writing service
machines which, starting from a parent reel of soft tissue or paper, give finished items such as toilet paper
rolls, kitchen towels, handkerchiefs, table napkins, handtowels (rolled or folded or interfolded) and industrial
towels
Figure 15 Basic Elements of converting

A Tissue Log Shredder is a machine that is specifically designed to shred tissue paper roll waste on the
production line. Once the material has been shredded down, the toilet paper manufacturer can easily dispose
of the waste or reuse it for recycling efforts
Below example displays a typical converting line for Tissue converting:
Level-2
Level-3-5
Figure 16 Model example of Converting Log Saw

Below Links can be accessed to view some of the systems modelled above:
Log Saw
The log saw machine for toilet paper roll is designed to accumulate toilet paper roll waiting for cutting. It
usually connects between toilet paper rewinding machine and log saw machine to makes sure there are
enough rolls for cutting, improving the production efficiency
https://www.iksinc.com/products/tissue-and-towel-converting/log-saw-blade-grinding-system
Slitter/Winder
https://www.youtube.com/watch?v=VIZ3z6Y8y5Y
Embosser
Embossing is used to increase the absorbency of paper towels. For the consumer market, embossing is also
used to increase the diameter of a roll of product (which is not desired in the Away-From-Home or commercial
market). ... In the absorbent tissue paper industry, these processes are often called finishing processes
Case packer
“Case packing” is really three distinct operations: case erecting, case packing/filling and case sealing.
https://www.packagingstrategies.com/articles/90716-double-duty-case-sealer-designed-for-snack-food-
manufacturing
https://www.youtube.com/watch?v=n-W2HAmmBwI

6.1.1.4 Buildings and Utilities
Building and Utilities would cover the general infrastructure such as offices, storerooms, Power sub stations
etc.
Figure 17 Example Model of Building Assets
Figure 18 Example Model of Utilities
Paper Mill Outlook
https://www.upmpaper.com/about-us/our-paper-mills/upm-kaukas-paper-mill/
6.1.1.5 Mill wide Systems and Equipment’s

General systems such as Fire Protection systems, Fuel systems, IT-systems, Mobile Equipment, Forklifts
which are supporting functions of the Mill are structured accordingly.
Figure 19 Example Model for Other support systems

6.1.1.6 General Attributes of Technical Systems
A Technical system generally holds dimensions and attributes by characteristics which help enable the
business to fulfil the below objectives:
• Completeness of Asset Information

• Flexible Search and Analysis
Concept of Classification is utilised with characteristics (not limited to) as below:
Characteristic Description
OUTPUT_RPM Output RPM
PSI Pressure Reading
PUMP_CURVE Pump Curve Number
SPEED Speed
SIZE Size
VOLTS Voltage
VALVE_SIZE Valve Size
COUP_TYPE Coupling Type
BLADE_COUNT Blade Count
DISPL Displacement
Table 5 Characteristics
The figure below in an example of Characteristics tied to a technical object:
Table 6 Characteristics on a technical object

6.1.1.7 Technical Object Types
Technical objects are further segregated and grouped using object types which can be used for extracting the
desired technical objects using standard reports.
Below is an example of typical object types(not limited to) used in the technical systems:
Figure 20 Technical Object Types

6.1.1.8 Bill of Materials
These can be defined as lists of components making up a more complex technical object or an assembly.
These lists contain material numbers of components, their quantities and units of measure (UOM). The
primary usage of maintenance BOM is to describe the structure of a maintenance object. The BOM’s are then
available in the work order for subsequent planning of maintenance work based on different types of
Technical object.
Below is a glimpse of BOM’s(not limited to) tied to a set of Functional Locations within the paper industry
Figure 21 Bill of Material

6.2 Measuring Points
Measuring Points are the physical or logical locations that are created against functional locations and
equipment to:
 Record physical asset utilisation, such as run hours, kilometres travelled, and tonnes moved, etc.
 Record the condition of a physical asset at a given time and date, such as temperature, pressure, flows,
etc.
Actual measurements are recorded on measurement documents. These measurement documents can be
added manually or can be automatically transmitted using interface.
The Functional Locations or Equipment’s as explained in sub sections above are monitored for safety and
reliability. Inspections and Lubrication is done on a regular basis and Measurements are taken at regular
intervals to keep the assets in ideal condition for safe day to day operations.
The sub-sections below explain some of the important measuring points mapped in S4HANA for different
asset types explained under sub-section 5.1.
6.2.1 Measuring Points
6.2.1.1 Measuring Points – Boiler system (Utilities)

Below are some examples of typical measuring points mapped in S4HANA for assets related to utilities:
Figure 22 Example of Modeled Measuring Points
• Record Flue Gas Temperature of a Steam Boiler Burner

• Record Feedwater Temperature
• Record Natural Gas Pressure
6.2.1.2 Measuring Points – Other Assets

Below are some examples of typical measuring points mapped in S4HANA for assets related to other assets
in located in certain premises or sections:
• Recording Eyewash station inspection

• Flue Eyewash and Safety tower inspection
• Sump pump inspection
Figure 23 Example of Inspection Tasks
https://www.safetyandhealthmagazine.com/articles/14834-choosing-an-emergency-eyewashshower-
station

6.2.1.3 Measuring Points – Paper Machine
Below are some examples of typical measuring points mapped in S4HANA for assets related to paper
machines:
Inspection of paper machine
• Guard/Nip check in a paper machine
http://www.technology-assoc.com/wp-content/uploads/DCP_1407-560x373.jpg
• Lead/Guide Roll Pressure Gauge
https://www.gettyimages.in/detail/news-photo/pressure-gauge-operates-on-a-newsprint-paper-
production-news-photo/450861280
• Head-Box Slice opening
https://projects.ncsu.edu/project/hubbepaperchem/EqipUnit/EqipUnit_Figs/Slide32.GIF
• Hydraulic Oil Temp in Basement
https://www.vega.com/en/home_kr/industries/paper-industry/hydraulic-oil-station
• Hydraulic Oil pressure

• No of Rolls Turning slowly
• Wire Tension (Gauge Reading)
• Oil level of a paper machine Broke check pump
• Oil level of a Refiner Gear Box within Stock Prep section of a paper machine
Valuation
based
recording
Figure 24 Example of Lube Oil condition measuring point

6.2.1.4 Measuring Points – Converting (Tissue)
Below are some examples of typical measuring points mapped in S4HANA for assets related to converting
assets:
• Unwinder- Belt inspection- Qualitative
• Embosser-Pulley/Sprocket inspections
6.2.1.5 Measuring Points – Drying

Below are some examples of typical measuring points mapped in S4HANA for assets related to drying
section:
• Cylinder inspection
Valuation
based
Figure 25 Example Model for Cylinder Inspection
• Yankee driver Oil level conditions

• Doctor Blade Inspection
https://swissremedies.files.wordpress.com/2012/05/dbassemb41.gif

Figure 26 Visual Inspections for Doctor Blades
6.2.1.6 Measuring Points – Pulping section

Below are some examples of typical measuring points mapped in S4HANA for assets related to pulping
section:
Inspection:
Chemical Tank Inspection:
Figure 27 Example Tasks for Tank Inspection
https://www.magnetrol.com/en/industries-applications/pulp-paper-mills/digester-blow-tanks
Lubrication:
Pulping Chemical additive system Oil level condition
Figure 28 Example visual tasks for Oil Level Condition
Other measuring points (not limited to) for condition-based maintenance are as below:
• Felt needle shower pressure within press section

• Yankee Pulper Consistency within a Broke section
• Yankee Motor Spool Starter AMPS
• Save all Pump Fan pump Amps
• Yankee dryer suction pressure roll- Lube oil temperature

Figure 29 Example Measuring Point for Oil Temperature Measurement on a Yankee Roll
Figure 30 Custom Table to manage limits on measuring points
These readings or measurements are recorded in the form of measurement documents which can be entered
manually or transferred to the S/4 HANA via an interface such as OSI PI. Readings transferred can be daily or
monthly as desired.
A few of the parts where the condition is monitored and measured with the help of measuring points is
mentioned in table 7 below.
In General measurements would include (but not limited to) the following:
Characteristic Type
Temperature Reading
Bearing Condition Code (OK/Not OK)
Cylinder Rod Inspection Code (OK/Not OK)
Suction Cup Inspection Code (OK/Not OK)
Gear Inspection Code (OK/Not OK)
Pressure Differentials Code (OK/Not OK)
Belt Inspection Code (OK/Not OK/Misaligned)
Conveyor Inspection Code (OK/Not OK)
Agitator Inspection Code (OK/Not OK/Abnormal Noise/Loose
Fasteners)
Air compressor discharge pressure Reading
Tie Condition – Timber Code (OK/Not OK)
Table 7 Characteristics for measuring points

6.2.1.7 Measuring Points – Entry List
Lubrication and Inspection rounds are performed on regular basis for key assets and their sub-systems.
Measurement Entry Lists are utilized for managing such measurements using measuring points.
1. The below process is followed for managing the inspection rounds
Figure 31 High Level Inspection rounds process
2. A custom FIORI app to manage the self-assignment of inspection work to technicians can be used
Figure 32 Self Assign Work
The inspection rounds hold an important place in the day to day functioning of the complex assets. Any
delays or misses in executing the round is monitored and represented as a KPI.
Once the technician or the operator self-assigns the work order, the job will be executed and confirmed.
The inspections of the next day are repeated, however if the system finds (batch job) any previous day orders
which were not confirmed, it will automatically mark them as “Missed” and Technically complete.
A report can then be executed to find all missed work orders for further action.
E.g. Lube round of a Palletizer which might contain tasks such as

Section-A
• Lubricate all Bearings

• Lubricate all Chains
• Lubricate Pallet Pusher
• Lubricate Pallet Stops
Section- B- Pallet Conveyor
• Check oil in reducers

• Grease Bolt Bearings on Conveyors
https://en.wikipedia.org/wiki/Palletizer#/media/File:In-line_Palletizer_by_OCME_S.r.L.jpg
Inspect
• Belts and Rollers

• Bundle Index Roller Belt
https://www.acsconveyor.com/bundle-conveyors
Figure 33 Typical Entry List

6.3 Task-Lists
Task lists can define and manage sequences of maintenance tasks centrally and use them for work
scheduling.
Typical examples of Task lists are mentioned in the table below:
Task list Type Discipline Description
General Winder Weekly Winder Mech Inspection
General Utilities Quarterly PM for Batteries
General Pulping Pulper Electrical PM
General Pulping Monthly PM Polymer Pumps
General Utilities Annual inspection on sump pumps
General Paper Machine Form Roll Drive and Coupling Inspection
General Paper Machine Quarterly Inspection of vacuum pumps
General Converting Log Saw Monthly Thermal Inspection
General Drying Yankee Dryer Grind/Clean
General Paper Wet End Auto Lube System Inspection
General Other systems Weekly Crane Mechanical Inspection
Functional Location Pulping Daily Pulper inspections
Functional Location Pulping 6 Monthly pulper agitator and drive PM
Table 8 Task list

6.4 Maintenance Plans
Strategy based plans are used for the preventive maintenance activities. Typical strategies are Daily, Weekly,
Monthly, Yearly.
Below are a few examples of Maintenance plans for various assets:
• Daily Tail Cutter Inspection

• Daily Gas leak checks of Burner Piping
• Daily operator rounds-Pulper
• 5 Weekly Case packer Electrical and Instrumentation PM
• Weekly Air compressor Filter cleaning
• 5 Weekly Winder E&I Preventive
• 2-Weekly Yankee Pulper Consistency Checks
• Weekly Broke Chest Instrumentation Calibration
• Weekly Infrared Bearing Scan
• Monthly Pulper Mechanical PM
• Yearly Fire detection alarm system inspection
• 4 Yearly Isolation Switch Examination
• 1 Yearly Non-Woven Machine Forming Section Fan Belt Inspection
• 1 Yearly Yankee dryer Journal Temperature check
• 3 Monthly Air Dryer cleaning
The figures below display typical maintenance strategies used with the maintenance plan.
Figure 34 Monthly Strategy
Figure 35 Weekly Strategy

6.5 Catalogs and Code Groups
The maintenance process involves a lot of activities ranging from Inspection to preventive maintenance .It is
imperative to record the root cause and actions taken on a critical asset for a streamlined reliability analysis.
Functionality of Code groups and codes in the form of Object Parts, Damages, Causes, and Activities are built
and used in the notifications for recording the findings.
E.g. Inspection on a paper machine will have findings related to Rolls and Cylinders such as Bearings,
Couplings, Gearboxes which can have codes as below:
1. Object Part –Air Bags,Actuator,Headbox sheets,Seals,Slice lip
2. Damage –Broken Corroded, Cracked, Loose, Missing, Out of Tolerance
3. Causes – Abnormal Wear, Creep, Erosion, Fatigue
4. Activities- Replace, Tighten, Weld
A few examples of the various code groups and codes are as mentioned in the below table:
Catalog Code Group Code

Object Part Mechanical Belts
Object Part Mechanical Brakes
Object Part Mechanical Chains
Object Part Mechanical Coupling
Object Part Mechanical Cylinder
Object Part Lubrication System Breather
Object Part Lubrication System Sight Glass
Object Part Lubrication System Piping/Tubing/Hoses
Object Part Lubrication System Bolts/Studs/Rivets/Locknut
Object Part Mechanical Belts
Object Part Mechanical Brakes
Object Part Mechanical Chains
Object Part Mechanical Coupling
Tasks General Adjust
Tasks General Align
Tasks General Balance
Tasks General Replace
Tasks General Fill
Tasks General Lubricate
Tasks Grease Lubrication Grease Piping Leak
Tasks Oil Level and Condition Oil Level Low
Tasks General Lubrication Lube Task Completed
Tasks General Adjust
Tasks General Align
Tasks General Balance
Tasks General Replace
Tasks General Fill
Tasks General Lubricate
Tasks Grease Lubrication Grease Piping Leak
Tasks Oil Level and Condition Oil Level Low

Catalog Code Group Code
Inspection Rounds Agitator Abnormal
Noise/Vibration/Temperature
Inspection Rounds Bearing Needs Attention
Inspection Rounds Belt Inspection Belt Worn/Frayed/Cracked
Inspection Rounds Belt Inspection Belt Slipping or Misaligned
Inspection Rounds Conveyor Inspection Conveyor Gearbox Leak
Inspection Rounds Cylinder Inspection Worn or Misaligned

Sprocket/Tensioner
Inspection Rounds Cylinder Inspection Mounting Bolts Loose
Inspection Rounds Fan Inspection High Bearing Temperature
Inspection Rounds Roll Inspection Cover Delaminating
Inspection Rounds Roll Inspection Abnormal

Noise/Vibration/Temperature
Inspection Rounds Doctor Blade Excess Blade Wear
Inspection Rounds Safety Inspection Some Flammables stored

improperly
Activities General Adjusted
Activities General Cleaned
Activities General Replaced Asset
Damage Mechanical Failure Leakage

Damage Mechanical Failure Deformation
Damage Operational Failure Overheating
Damage Operational Failure Parameter Deviation
Damage Material Corrosion
Damage Material Fatigue
Causes Installation Fabrication error by Manufacturer
Causes Mechanical Yankee Head /Shell
Causes Other Improper Procedures
Causes Other Lack of Lubrication
Causes Other Maintenance Error
Causes Other Lack of Lubrication
Causes Other Improper Alignment
Causes Design Improper Design
Table 9 Sample Catalogs

7 Principles of Reliability and Centralized master data
7.1 Centralized Master data
The figure below displays the approach taken by such industries to drive a consistency in the planning
process across the different systems.
In general, the maintenance program adopted by most of such industries is regulated and maintained such
that the reliability and availability of systems is kept high as per standards.
A centralized approach to manage the master data of key components is followed and applied across all
manufacturing mills as below:
• Centralized Task lists(create,update,delete)

• Centralized BOM(create,update,delete)
• Centralized Maintenance Plans
7.1.1 Centralized Task lists
1. The figure below highlights the centralized task list maintenance process:
Figure 36 Task list Maintenance Process

2. A program facilitates creation of same Task list with New Group Counters to all relevant plants.
Appropriate validation messages appear for the user to make corrections.
Figure 37 Program to extend Task lists
3. Validations and Reservation of Group Counters is held dynamically
Figure 38 Validations
This process adds value as below:
• Ensuring to reduce the time to plan similar jobs executed in the past which otherwise would need
different manuals, procedures to be referred and cause potential delays
• Feedback after job from technicians is an important aspect of fine tuning what was missed as a job
step which could help understand the right procedures. This helps to maintain a centralized repository
of latest procedures and applied throughout the manufacturing facility
• Ensures that estimates on planned working time are as accurate as possible to drive maximum
efficiency

7.1.1 Centralized Bill of Material
1. The figure below displays the process for maintaining centralized BOM:
Figure 39 Centralized BOM process
2. A custom program facilitates transfer of BOM items created centrally to all relevant plants.
Appropriate validation messages appear for the user to make corrections. E.g. Material not extended
S4 HANA inbox message items appear to the local master data owners on any updates to the
centralized BOM.
Figure 40 Program for extending BOM

Figure 41 Validations and Workflow
Figure 42 Final use of Material BOM in Technical object
This process adds value as below :
• Ensuring that right parts are available for planning

• Ensuring that adhoc-parts needed are quickly available to view in the structure of the asset
• Ensuring that asset structure is updated consistently across manufacturing facilities

3. A work process is followed to have a seamless BOM creation and update process using Notifications
and Work items as below:
Table 10 BOM master data management process
4. The local owners can then review all the technical objects to which a common BOM can be applied
and use a custom FIORI app to establish the link in mass:
Table 11 Establish construction type link on technical object

7.1.2 Centralized Maintenance Plans
1. The figure below displays the process for maintaining centralized Maintenance Plan:
Figure 43 Copy Maintenance Plan
2. A custom program to facilitate the creation of plans using a centralized plan is available:
Figure 44 Program to create plans from reference
This process adds value as below:
• Ensures that maintenance programs are followed consistently across facilities where ever possible
• Ensures single source of truth for applicable maintenance strategies
• Saves time for creation of maintenance plans for multiple assets without duplicity of information

7.1.3 Centralized Reference Equipment
A reference Equipment concept holds the standard information such as technical attributes based on Material
and Object types and helps to manage the following:
1. Update master data information on new maintainable serialized Equipment’s after Goods receipt in
Stores
2. Provides an ability to automatically/manually run a batch job to manage the updates as needed
Figure 45 Reference Equipment
3. Data such as long text, measuring points, classification, documents, permits, construction type,
partners etc. is carried over to the maintainable Equipment(s).
Figure 46 Update Flow(High Level)

7.2 Measuring Points for Condition Based Maintenance
Measuring points as explained in sub-section 5 above would have limits of a parameter which when exceeded
would trigger an alarm in the control system of the plant. Certain parameters are critical and drive the need to
carry out corrective tasks. These parameters are then mapped to measuring points and stored with upper and
lower limits in the S4 HANA System. Process systems operate with more than one type of limit to measure the
effectivity of process defined by manufacturers and operators e.g. Process upper/lower limit, Safe Upper and
Lower limit. In order to map these limits individual measuring points can either be classified or mapped as
separate measuring points which results in data maintenance becoming high.
A specialized framework is adopted to manage the condition-based maintenance where in the process limits
are stored in a common table maintainable by the user manually or in-mass and indicate the action which
needs to be triggered based on the deviation of the process parameter i.e. a notification or a work order. This
gives the following advantages:
1. Centralized Framework for managing parameters

2. Mass upload mechanism for all parameters
3. Dynamic control of Condition based action per measuring point i.e. A Work order or a Notification
4. Capability to be interfaced to a real time system for managing limits if applicable
Figure 47 Condition Based Maintenance

Figure 48 Different Limit Ranges for measuring points
Figure 49 Dynamic Control for corrective action
7.3 Managing Reliability based Maintenance using custom solution

Reliability analysis plays an important role to understand the key assets and failure modes which can impact
the overall ecosystem and pose a threat to health, safety and environment. It is imperative for such asset
intensive industries to capture the risk and criticality information for analysis such that suitable corrective and
preventive actions can be taken based on Failure Mode Effect analysis.
1. A mechanism to store the probability and criticality per failure mode is stored in a custom table
Objec Catalog Profile Damag Descriptio FLO Probabilit Impac Safety Throug Qualit
t Type e n C y t Impac h put y
t impact Impact
PUM Z_CENTPUM 001 Fatigue 9 1 1 1 1
P P
Figure 50 Manage criticality and probability for failure modes
2. The cost of event is ranked using a ranking list
Figure 51 Manage Cost Impact Ranking Scores
3. Each of the Failure mode is then analyzed using a custom report to analyze the existing event rate and
create or adjust a preventive maintenance program or corrective tasks or condition-based recording.
The report drives data from:
a. Notification and its damages

b. The risk, criticality and probability values
c. Cost associated with each event
d. Ranking of cost based on a custom table

4. List of Events are displayed with the Risk Number(calculated) = Probability* Severity of Impact
(RMS)*Cost Factor
Figure 52 Risk Numbers
Figure 53 Event Detail

Figure 54 Event Trend
5. Top events are analyzed, and optimum strategy is then proposed using the below custom table for
each failure mode.
a. E.g. Pump Fatigue events should follow the following corrective steps using a Task list
b. Exceptions on different strategies for an asset based on its application can also be adopted .e.g.
Pump carrying water vs pulp might have different failure rates hence would need different strategies
Object Catalog Profile Damage FLOC Counter Maint TLType TLGrp GrpCounter Measuring
Type Plan Point
PUMP Z_CENTPUMP 006(Fatigue) 1
PUMP Z_CENTPUMP 006(Fatigue) 2 A 1000 1
Figure 55 Strategy proposal
c.
The strategy proposed can be in the form of a Maintenance plan(Centralized) with a defined
frequency which can be used to copy and create local maintenance plans’ All sump pumps to be
monitored every 3 months instead of 6 months.
d. A centralized Task list which can be adopted locally for specific type of assets
e. A measuring point which can be used for condition-based maintenance
6. The maintenance strategy is accordingly revised or updated based on the failure events to reach to an
optimum failure rate.
7. A corrective maintenance Notification can then be triggered to initiate the corrective or preventive
actions as recommendations from FMEA
8. The Centralized plans and Task lists can then be adopted by individual manufacturing facilities using
the copy functions as mentioned under sub-section 6.1 and 6.2
The figure below highlights the integrated process of FMEA

Figure 56 Integrated FMEA
Figure 57 Analysis

8 Business Roles Involved
The following business roles are generally applicable in such industries.
Roles Description
Local Master data administrators Manage local changes such as FLOC, Equipment
Central Master data administrators Manage Central Changes such as Task list
Maintenance Planner Manages Work order planning
Scheduler Manages Scheduling and Dispatch of Work orders
Initial scrutiny of Notifications raised for
Gatekeepers missing/additional information
Technician Execution of Work Orders including Confirmations
Work Order approver Approve/Reject work order cost permits
Process Safety Coordinator Manage Safety related data in Functional Locations
or Equipment
Operators Perform Small Fixes
Reliability Engineers Manage the FMEA and Reliability Analysis
Table 12 Business Roles
9 General Process Overview

The following high-level processes are followed :
1. Corrective- Repair, Rework, Compliance

2. Unplanned- Trouble shooting, Rework, Repair
3. Time based – Internal inspection, Inspection Rounds, Preventative work
4. Project Work (Capital/Expense)- Modification, Capital, Small projects
5. Condition based- Inspection rounds, Oil analysis
6. Fix it my self- for the operators/technicians to do the small fixes by themselves
7. Refurbishment- For Rotables
The maintenance work is sub-classified as below(not limited to) to get accurate reporting and analysis:
Figure 58 Sub-Classification of Work

The figure below highlights a typical work process:
Table 13 Work Order High Level Process
The high-level steps are detailed as below:
1. Notification is created describing the problem- Desktop and Mobile

2. Notification is reviewed and updated for additional information- Desktop and Mobile
3. Notification is approved and converted to a work order-Desktop and Mobile
4. Work order is planned and approved with automatic budget set up(enhanced)- Desktop and Mobile
5. Work order is scheduled and dispatched- Desktop
6. Work is executed
7. Work order is confirmed- Desktop and Mobile
8. Work order is closed- Desktop
9. Action on any feedback such as Master data update is initiated for future planning
10. Closure of Work order

9.1 Key Custom Functionalities used/Built
The following are an approx. count of key custom functionalities built/used to perform a seamless end to end
maintenance process work cycle:
Figure 59 High level Object Summary(approx)
The IPSEC process model followed is as below:
Figure 60 IPSEC key features

The details of each of the key features are explained below:
1. Enhanced FIORI app for managing notifications

a. Dynamic field control based on Notification type
b. Customized Long Text Questionnaire based on Notification type
2. Custom FIORI app for managing tasks and its completion
3. Custom FIORI app for creation and change of work order on mobile and desktop with integrated
features:
a. Dynamic Material availability
b. Integration with EWM for pinpointing the exact location of spares
c. Integration with 3D viewer for pulling parts from 2D and 3D drawings using Visual Interaction
Tool Kit
d. Barcode Scanning of Technical Objects
e. Task list inclusion
4. Automatic update of Estimated Costs from Planned Costs- This helps analyse the variance between
actuals and planned to understand the effectiveness of planning post closure of work order
5. Work Order approval based on Levels with Workflow
6. Flexibility for approver update for each level based on distribution lists
7. Workflow items in S4HANA inbox for approval and rejection notes
8. Automatic Budget set up for each work order on Release based on Estimated costs
9. Mass assignment of Project to Capital Work Orders
10. Custom FIORI app for execution of work order operations on mobile and desktop
a. Work Start and Stop Features
b. Record Measurement Readings
c. Perform Dismantling of Equipment
d. Record Feedback on work
11. Custom FIORI app to view all documents attached to Technical objects or Measuring points and Task-
lists on Mobile and Desktop
12. Custom FIORI app to self-assign work to technicians

Below sub-sections provide a glimpse of the planning and execution on mobile platform:
9.1.1 Notification initiation and approval using custom FIORI App
A notification can be raised to initiate a repair or an emergency work on various Technical objects:
Figure 61 Notifications using FIORI

Feedback is provided in Notifications, and are managed using Tasks which are controlled and approved
using below custom FIORI app:
Figure 62 Task Processing
9.1.2 Notification phases
During the life cycle maintenance request goes through various stages which are managed using system and
user statuses (sequential and non sequential) as below:
Figure 63 Sequential user status
Figure 64 Non- Sequential user status

9.1.3 Work Order planning using custom FIORI App
Figure 65 Work Order planning-1 using FIORI
Figure 66 Work Order planning-2 using FIORI and 3D

Figure 67 Ariba Catalogs
9.1.3 Work Order Budgeting and Approval
The Work orders are budgeted automatically based on defined custom rules. An example of defined rules is
as below:
Figure 68 Budget derivation
The workorders are approved using custom solution based on planned costs to achieve a sustained control
on key expenses.
Table 14 WO approval workflow

9.1.5 Work Order Scheduling
MRS is used as a scheduling tool replacing the conventional Capacity leveling in GUI.
1. This helps in managing a integrated workschedule of employees

2. Provides inbuilt overview capability of balancing capacity vs demand
Figure 69 MRS Scheduling Elements
Figure 70 Scheduling using MRS
A few custom enhancements facilitated streamlining of resources between the S4 and MRS landscape.
Movement of Resources between work centers is inevitable hence an easier approach was built to mage the
process using a simplified UI highlighted below:
1. Provision to view the existing resources and transfer to another workcenter is built using a simple
selection of one or more personnel numbers
2. Consistency check between MRS and S4 is important which is also available as apart of this utility
program

Figure 71 Transfer Resources between Work centers
Figure 72 Inconsistency check between MRS and S4

9.1.6 Execution using custom FIORI App
1. Mobile devices display the current and on-going work which can be completed while being on the
shop floor. The key highlights within the execution process are as below:
Figure 73 Work Execution using FIORI
Figure 74 Equipment Install/Dismantle integrated with stores

2. It is a regular practice for the technicians to go through the standard operating procedures, drawings
etc for which a custom mobile app is enabled which can facilitate search of documents assigned to
technical objects or measuring points or task lists using extended classification functionality.
Figure 75 Search Documents
3. Finding spare parts for repair is a common scenario in maintenance. The custom material search app
facilitates the search of material right to the Bin location using long text string search.
Figure 76 Material Search with Stock

9.1.7 Work Order Phases
During the life cycle maintenance work order goes through various stages as below:
Figure 77 Header Sequential user status
Figure 78 Operation User Status
9.2 Specific Functionality to use 3D VE

S4HANA 3D Visual Enterprise Solutions combine visual product, plant and process information with textual
business content to provide an unprecedented combination of traditional business information with fully
interactive visuals.
The key modules that support the product are:
 Visual Enterprise Generator- Licenced
–This module generates a neutral visualization file used by the other modules in the solution package
from almost all (around 150) existing CAD and geometry formats. The generated files are lightweight
and have only a fraction of the size of, for example, CAD files
 Visual Enterprise Author- Licenced
- This module allows animations to be generated from 3D data that are used, for example, in operating
manuals or assembly instructions.
 Visual Enterprise Viewer

- The Viewer is integrated into all S4HANA applications and requires no additional license fees. It
permits representation of the model in differing formats including so-called thumbnails, i.e. small
graphical icons that give a highly simplified image of the actual model
The author was primarily used to manage the creation of hotspots in 2D drawings and add meta data to the
various parts.
1. The existing drawings were of nature .SVG or DWG which had to be converted to a VDS/CGM format
by the engineering department
2. The standard viewer has some limitations on the usage in the conventional GUI platform
3. Limitations on the Visual interaction tool kit to read CGM files which were primarily supported for 2D
drawings
4. Visual interaction tool kit was used to expand the functionality for the custom apps and trigger the
retrieval of parts information from the drawing in a VDS format
5. The parts could be finally selected and added on the work order operation.
The process adds a lot of value as below:
• Ability to search parts directly in an integrated manner via a visual drawing or manual which made the
planning much easier
• This facilitated the planners and technicians to provide Realtime information to the engineering team
for any updates or modifications to the drawings
Figure 79 Pull apart,Rotate,Reassamble options
Figure 80 Copy spare parts from 3D drawing into work order

SAP visual interaction tool kit is utilized to enable the 3D VE on custom mobile apps
Figure 81 SAP SDK
9.3 Key Integration areas

The plant maintenance component is integrated with the following key modules/process areas:
Figure 82 Key integration Areas

10 Key KPI’s
The following are some of the key KPI’s (not limited to) which are monitored to measure the effectiveness of
business processes:
Note: The images are drawn to represent the concept for visualisation of the metrics and do not represent any
actual image from a system.
1. Approval Efficiency of Notifications (Based on user status usage, it is imperative to understand a

measure if the notifications are being raised out of turn which are rejected)
- % trend of Rejections period wise
- % of Rejections Plant wise to represent the overall health
Figure 83 % of Rejections/Total Notifications Raised
2. Work order planning efficiency – No of work orders with Actual hours vs planned hours deviation
- Represents the difference of the estimates and actual man hours in order to stream line the job
plan estimates on a continuous basis
Figure 84 % of Work orders with deviation in planned/actuals

3. Total Maintenance Costs
Figure 85 Maintenance Cost Tend Chart
4. % of Labour/Material/Services cost of the Total Maintenance costs
Figure 86 Break-up of Maintenance Costs
5. Actual Manhours by Work Order type

6. Work Order cycle time in Days (Time from creation of Notification to work order Technical completion
date)
Figure 87 Work order cycle Time
7. Overdue Work Orders (Orders in Progress where Basic Finish date< todays date)
8. % of Work orders using Task list
- This helps to have a figure of planners using manual estimations or using standard job plans for
consistent planning.
Figure 88 % of Work Orders without Task lists

9. Work Order Execution Adherence %
- Work orders which are confirmed within the stipulated Basic dates
Figure 89 Execution Compliance
10. Schedule Success

- Metrics to display the success of weekly schedule of operations dispatched vs confirmed
Figure 90 Schedule Success %

11 Interfaces
Typical Manufacturing industries use legacy systems to manage the operational and safety aspects to drive
the overall equipment effectiveness with some in-built calculations. Such systems need some important
equipment data such as its capacity and other factors stored as either classification records or direct field
entry in order to store updated information.
Interfaces are established to streamline the data, where S4 HANA becomes the driving system. Some key
interfaces (not limited to) are as below:
Figure 91 Interfaces
12 Key Transactional Metrics

A typical metrics measured for medium to largest mill on the major transactions carried out in plant
maintenance is as below:
Figure 92 Metric on Key Transactions

Metrics for the largest Mill within 1 Month of Go- Live
Metrics(1Month after Go live for largest Mill)
35000
30000
25000
20000
15000
10000
5000
0
Total WO Total Operations Confirmations
created Notifications
Figure 93 Key Metrics for the largest Mill
13 General Industry Technical Terms(Source as in section 14)

1. Broke- refers to partly or fully manufactured paper or board that is discarded from paper or board
making, converting, and finishing processes. It also refers to the stock made by re-pulping these
materials. Broke is continuously being produced and it is the job of the “broke system” to collect this
valuable resource and supply it back to the paper or board making process for reuse.
The purpose of broke cleaning and screening systems is to remove contaminants from the broke
stream, break apart fiber flakes and bundles in the broke to improve sheet uniformity and minimize
fiber losses, and return a clean, consistent flow of broke to the machine furnish.
2. Coarse screening- is one of the first separation processes in a recycled fiber facility and
its purpose is to remove contaminants that are significantly larger than the fibers.
3. Lignin- is left in the pulp to bulk up the paper, increasing the yield from a given amount of
wood. Pulp intended for use in fine papers, on the other hand, is prepared by cooking
to remove the lignin, as well as to separate the fibers. Most of the remaining lignin is removed by
bleaching
4. Waste paper baler- is a paper compactor machine which is used to compress and bale the
waste paper like office waste paper, paper scraps, as well as old newspaper into a cube. … It is a
very important step of the waste paper recycling. So, Waste paper makes the recycling process more
efficient
5. Carbon dioxide (CO2)- is widely used in the paper industry today. It is used in paper machines to
adjust and stabilize pH, to buffer the papermaking system, to decrease calcium levels, or to increase
dewatering
6. AGITATOR – Propeller or agitating shaft for stirring the pulp suspension in a chest or tank. (2) A
rotating device for mixing fluids and fluid suspension in a tank or chest

7. CHEST- Vessel equipped with an agitating device for storing, collecting, mixing and/or chemical
treatment of pulp suspension. A large vessel fitted with an agitator for storing pulp stock
8. CHIPPER- A machine that chips logs after de-barking
9. CONVERSION-Subsequent process that paper or board undergoes after manufacture but before
being sold to the customer
10. DEFIBRATION- Separation of wood fibers by mechanical and/or chemical means
11. DIGESTER- Pressure vessel used to chemically treat chips and other cellulosic fibrous materials
such as straw, bagasse, rags etc, under elevated temperature and pressure in order to separate
fibers and produce pulp
12. EFFLUENT-Waste backwater and rejects from which fiber is recovered prior to discharge from the
mill
13. ACCEPTS-Stock after it has been subjected to some cleaning processes
14. CREPING- Creping of paper on the paper machine using a large drying cylinder known as a Yankee.
15. DANDY ROLL OR WIRE ROLL- A hollow roll with varied coverings, usually metal, that compacts the
fibers and applies finish characteristics e.g. a watermark
16. DOCTOR- A metal or synthetic weighted blade which bears against rolls and cylinders in order to
keep their surfaces clean
17. FIBER- Examples include woods (softwood, hardwood), bastes (flax, hemp), grasses (straw).
Elongated, tapering, thick walled cellular unit that is the structural component of woody plants. Wood
pulp comes from softwood trees such as spruce, pine, fir, larch and hemlock, and hardwoods such as
eucalyptus, popular, aspen and birch
18. HEAD BOX- Device for applying and distributing stock onto the wire that keeps fibres from clogging
together so that a consistent formulation can be achieved. Also known as a breast box or flow box
14 Appendix for Source of Reference Information
Source Link
Paper Making Terminology https://www.pita.org.uk/images/PDF/Glossary_of_Terms.pdf
2017 Production Figures https://www.statista.com/topics/1701/paper-industry/
Largest paper machine http://www.industrytap.com/worlds-largest-paper-machine-
automated-efficient-sustainable/18732
Paper Products https://www.google.com/search?q=paper+products&rlz=1C1GCEB
_enIN836IN836&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiVt6
SsxrLmAhU0heYKHdqPAqcQ_AUoAXoECA8Qaw&biw=1422&bih=64
2
Digital Packaging https://worldpapermill.com/paper-pulp-industry-future-trends/
Other pictures/definitions Wikipedia/google
Table 15 Other References


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APER (SAP COE)

Gupta & Gaurav S

A Glimpse of SAP S4HANA EAM-Plant

3 Overview of Industry Process &Types of Assets ....................................................................... 6

3.1 General Overview .............................................................................................................. 6

5 Typical Maintenance Organizational Structure ........................................................................ 17

5.1 Maintenance Teams/Work-Centers.................................................................................. 18

6.1 Functional Location and Equipment ................................................................................. 19

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 2

7.1 Centralized Master data ................................................................................................... 45

9 General Process Overview ..................................................................................................... 57

9.1 Key Custom Functionalities used/Built ............................................................................. 59

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 3

13 General Industry Technical Terms(Source as in section 14) ................................................ 77

14 Appendix for Source of Reference Information .................................................................... 78

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 4

• Provide a high-level understanding to EAM-Plant Maintenance Functional Consultants and

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 5

Note: This document is for internal knowledge sharing purpose only.

3 Overview of Industry Process &Types of Assets

3.1 General Overview

Figure 1 Market demand study

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 6

Table 1 High level process overview

Figure 2 Some Facts

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 7

Graphic E.g. Newsprint and Writing

Packaging E.g. Carton Board and Container Board

Others E.g. Tissue

3.3 Known Paper Industries

Figure 4 Known Paper industries

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 8

Figure 5 Basic pulping process

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 9

• Wet section/Forming Section

Refer links below for images of a paper machine:

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 10

 Pulp Processing Machines/units

 Plant and Machinery/Other support Equipment’s

Facilities Control System Plant &Machinery

Processing Units Paper Manufacturing Packaging

Figure 6 Key asset types

The details of key assets are explained under sub-sections below.

3.6.1 Pulp Assets

The main components of the pulping system are:

• Pulper comprising of Agitators, Conveyors, Exhaust Fans, Lube Oil System

• Fiber Recovery systems

• Stock Storage systems such as Stock Chest

• Sump water system including Effluent storage

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 11

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 12

Some important functions are as below:

• Fire protection systems

3.6.3 Paper Machines

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 13

A typical example of converting section would be as below:

Figure 7 Converting Line

Some of the key sections of a converting unit are as below:

A Glimpse of SAP S4HANA EAM-Plant Maintenance Solution in Paper Manufacturing Page 14

4 Importance of Modelling Technical Assets and S4HANA Maintenance

• It is a high maintenance or operational impact asset

• There are operational or maintenance requirements to record statistical details