SAP Plant Maintenance

Calibration of Equipment

04.2024

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Content

1. Calibration Overview
2. Calibration of Equipment Process Flow
3. Calibration of Equipment Step by Step Via SAP
3.1 Create General task lists creation
3.2 Create Maintenance plans
3.3 Schedule calibration plans
3.4 Calibration Order creation
3.5 Scheduling Overview list
3.6 Change order & Release Order.
3.7 Results Recording & UD
3.8 Overall completion confirmation: Order operations’ time confirmation
3.9 Technical completion of Order
3.10 Period end Settlement of Order
4. Process Calibration Test Template
5. Transactions List
6. Glossary

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 1. Calibration Overview

Calibration is the process of evaluating and adjusting measurement devices to achieve true
accuracy. When equipment is calibrated, you can be sure that the readings are accurate and
precise.

Equipment calibration programs are an essential part of precision maintenance and will need to
be carefully planned and executed to be successful.

This scenario describes how to process the test or measurement equipment in a calibration

inspection.

The objective of a calibration inspection is to determine whether each piece of equipment specified

in the maintenance order meets the predefined performance specifications.

• Inspect the equipment specified in a maintenance order

• Record inspection results for each piece of equipment

• Valuate each piece of equipment

• Make the usage decision for the inspection lot

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 2. Calibration of Test Equipment Process Flow

The complete functionality of the test and measurement equipment management of SAP (PM and QM
module) is used in the calibration area. Since the different test equipment dimensions were unable to be
implemented the project group decided to use the classification system in the test and measurement
equipment management.

Amongst other things the dimensions of all test equipment are defined in this classification system,
because for calibration dimensioning print outs in large and small letters have different meanings and as
a result different test methods must be carried out.

Possible double procurement can be avoided since through the introduction of the classification system,
measurement equipment can be found quickly e.g. through the search term “size”, “tolerance field”,
“precision” or “special characteristic”.

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 3. Calibration of Equipment Step by Step Via SAP
3.1 Create a Maintenance Plan for scheduling Calibration work
•T-code: IP01

Usually calibration work is recommended as a Periodically Planned work

3.2 Creation of Master Inspection Characteristics

•T-code: QS21

•Enter the Plant, Validity start date and reference characteristics (have used PRESSUREMEAS as reference
characteristics)

•Control Indicators are critical while creating MICs and a Sampling procedure (based on Fixed sampling
with sample size 1 assigned). Catalogs can also be assigned

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3.3 Create Equipment Task List with Inspection point
•T-code: IA01

•Inspection points 300

•assigned MIC’s again at operation

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Remark
Note that to classify a Task List as a Calibration Task List for Equipment, Inspection point 300 is selected
under Task List -> Header -> QM Data

In Operation screen, enter the Operation details and assign MIC or MIC’s to operation. A sampling
procedure TESTEQPT (as created in QM) also assigned at MIC level

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Save the Task List

3.4 Maintenance Plan is scheduled to generate a Calibration Order

•T-code: IP10/IP30

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3.5 Release Calibration Order
•T-code: IW32
• Enter the order number in the Initial screen
• Click on the release flag button to release the order. After the order was released system status
changed from CRTD to REL.

➔ Save the Order

After Releasing the calibration order we can check the inspection lot details and record the results.

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Remark

Calibration maintenance order User status should be maintained as per the priority of the maintenance
work.

The following user status will be available in the Calibration maintenance work order.

3.6 Check Inspection Lot

•T-code: IW32

• Enter the order number in the initial screen

• Next, go to the Environment icon and check the inspection lo

➔ Check the inspection lot no

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Remak : “Carry out calibration task, and process the Calibration order”

This is as per current standard process and hence niot been detailed further
Labour hours (internal) are booked to order, Materials if any are Issued (Stock material)/GR (Non stock
material), Service entries (in case of external service) are recorded against the Calibration order

3.7 Results recording for Calibration Order

Record inspection results for each MIC to determine whether the recorded values are within the
predefined inspection specifications. Based on the inspection results evaluate and close each operation.
The valuation specifies whether you accept or reject the equipment at the operation level.

•T-code: QA32
• Enter Plant details.
• Enter the Lot creation date.
• Inspection lot origin-14
• Select all Inspection Lots indicator
• Press execute icon to display the list of Inspection Lots.

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• On the next screen, you can see Inspection Lot details
• Check the inspection lot status as REL CALC which indicates that inspection specifications are copied in
the inspection lot and the sample size is calculated.
• Select the inspection lot & press the “Results” button, to do the resulting recording.

• After clicking on the result button, the Inspection tab will be opened, here click→ “Assigned Insp. Point”

• The “Result Record Overview” screen will be opened and record the results against all the line items.
• Select all operations and press evaluate button.
• Click on the lock icon and save it.

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• At the time of saving valuation tab will be popup, here select the confirmation icon & do the
confirmation.

• Enter actual work and unit and click on the back button

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3.8 Usage Decision for Calibration Order

The usage decision for an inspection lot confirms whether you accept or reject the equipment.

• T code :QA32.
• Select the inspection lot & Press the usage decision button to move to the next screen.
• Select the UD code from the dropdown functionality

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 ➔ Press the save icon.

Note: After the Usage decision Calibration Order will be “TECO” automatically. After the usage decision,
automatically the system status will be set to TECO.

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3.9 Calibration Certificate
•T-code :IW32
• Click on the order icon and select the print option to get the Calibration certificate. As shown in the
below screen.

➔ Select Output Device → ZPDF to fetch the certificate from order.

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• Select the checkbox indicator of the calibration form and click on Print Preview
Note :
• For Safety Valve Calibration Order- Select ZPM3 print key
• For General instrument Calibration Order- Select ZPM2 print key

3.10 Time Confirmation & Technical Completion of Calibration Orde

• T-code : IW42
• Actual Duration

3.11 Settlement Process for Calibration Order

The actual cost of consumption (materials and external services) for Maintenance orders is loaded on the
order itself as and when resources are consumed during the order processing cycle. At the month-end
finance, Department settles the actual cost of all the maintenance orders which are technically completed
to the respective cost centers. After the settlement, the actual cost of the order is transferred to the cost
center, and the actual cost of the order will become zero.

• T-code : KO88
• Set Controlling area screen will pop up, here need to provide the controlling area “HPCL”.
• The Settlement screen will be opened, here provide relevant details. → Settlement period, Fiscal Year &
Processing options tab - Click on the check transaction Data icon
• After that Maintenance Order cost will be settled to the settlement receiver.

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3.12 Business completion for Calibration Order

•T-code→ IW32.

➔ After completion, the system status changed from TECO to CLSD (closed).

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 4. Process Calibration Test Template
N ACTUAL Ok/No
Business Process Steps T-code Input Data EXPECTED RESULTS TESTER
o RESULTS k
Task list type – Task lists to Task List Gr:
Create General task lists A(general) be created GRCR:
creation Description:
Calibration Task
lists_QAS
1. IA01 Usage : , Status
Inspection points :
Strategy:
MIC:
Main Work center :
Create Maintenance Maint. plan cat: Plan should
plans Equipment: create . Calibration Plan:
Order Type:
Call horzon:
Shift factor Early&
2. IP42/IP41
late compl.:
Factory Calendar:
Scheduling period:
Task list:, Gr:
,Grcr:
Schedule calibration Calibration plan: Plan should
plans IP10 get
3.
scheduled

Calibration Order Order type – Scheduled Order

creation Planning Plant - call objects number -
IW31/IP10 Maint. Work (Order)
4.
center : should get
Priority - generated

Scheduling Over view Maint.Plan- Maintenance List display

list Plant - plan with with call
5. IP24 scheduling objects
dates

Change order & Release CCkey: Order Change

order Duration Unit : operation required
Activity type: assignments. field and
6. IW32
Inspection lot: save
Equipment:
Cntrl Key:

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 Results Recording & UD QA32 Date range Results Results
7. List setting: Recording & are
Inspection lot: UD accepted
Results :
UD:
IW41/IW42 Order no. All the
8. Operation nos., operations
Overall completion Order
Personal confirmed.
confirmation: Order confirmed
number:
operations’ time Order status: with status
Actual Time data
confirmation CNF (confirmed) CNF
for order
operations.

Technical completion of TECO command. 1) Order closing

Order with status TECO Order
Confirm the actual completed
together with.
completion date-
for next schedule 2) Order will
calculation
only be saved
9 IW32 after status
TECO when all
the operations
have been
confirmed
(status CNF).

Period end Settlement -Controlling Costs in the TOTAL ACTUAL

of Order -Order Number order settled to COST OF ORDER
-Settlement SETTLED TO CTR
the cost center
period:
-Fiscal year: defined in the ……..
K088/KO8G -Processing type settlement rule.
9 Actual cost of
order became
zero. Cost
element:

Date:
Name of Consultant :

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 5. Transactions List
Code Description Code Description
CA85 Replace Work Centre IP24 Maintenance Scheduling Overview List
CS03 Display Material BOM IP30 Deadline Monitoring
IA01 Create Equpment Task List IP41 Create Single Cycle Plan (R4 onwards)
IA02 Change Equipment Task List IP42 Create Strategy Maintenance Plan (from R4 onwards)
IA03 Display Equipment Task List IQ01 Create Serial Numbers
IA05 Create General Task List IQ02 Change Serial numbers
IA06 Change General Task List IQ03 Display Serial Numbers
IA07 Display General Task List IQ04 Serial Numbers List Editing - Create
IA11 Create Functional LocationTask Lists IQ08 Serial Numbers List Editing - Change
IA12 Change Functional Location Task List IQ09 Serial Numbers List Editing - Display
IA13 Display Functional Location Task List IR01 Create Work Centre
IE01 Create Equipment IR02 Change Work Centre
IE02 Change Equipment IR03 Display Work Centre
IE03 Display Equipment IW13 Material Where Used List
IE03 Display Equipment IW22 Change Notification
IE05 Equipment List Editing - Change IW23 Display Notification
IE08 Equipment List Editing - Display IW24 Create Notification
IH01 Display Functional Location Structure IW25 Create Notification
IK01 Create Measurement Point IW26 Create Notification
IK02 Change Measurement Point IW28 Notification List Editing - Change
IK03 Display Measurement Point IW29 Notification List Editing - Display
IK07 Measurement Point List Editing – Display IW30 Notification List Editing - Display Multi Level
IK08 Measurement Point List Editing - Change IW31 Create Work Order
IK11 Create Measurement Documents IW32 Change Work Order
IK12 Change Measurement Documents IW33 Display Work Order
IK13 Display Measurement Documents IW38 Work Order List Editing - Change
IK17 Measurement Documents List Editing - Display IW39 Work Order List Editing - Display
IK18 Measurement Documents List Editing - Change IW40 Work Order List Editing - Display Multi Level
IK21 Measurement Documents List Editing - Create IW41 Time Confirmation - Indvidual Entry
IK22 Measurement Documents List Editing - Create IW42 Overall Completion Confirmation
IK22 Measurement Documents List Editing - Create IW44 Time Confirmation - Collective Entry no Selection
IK41 Measurement Documents List Editing - Display Archive IW48 Time Confirmation - Collective Entry with Selection
IL01 Create Functional Location IW64 Change Notification List of Activities
IL02 Change Functional Location IW65 Display Notification List of Activities
IL02 Change Functional Location IW66 Change Notification List of Tasks
IL03 Display Functional Location IW67 Display Notification List of Tasks
IL05 Functional Location List Editing - Change IW68 Change Notification List of Items
IL06 Functional Location List Editing - Display IW69 Display Notification List of Items
IP02 Change Maintenance Plan IW8W Goods Receipt for Refurbishment (R4 onwards)
IP02 Change Maintenance Plan KO88 Settle Order (Single)
IP03 Display Maintenance Plan MB11 Goods Movement
IP03 Display Maintenance Plan MB31 Goods Receipt
IP04 Create Maintenance Item ME21 Create Purchase Order (pre R4.6)
IP05 Change Maintenance Item ME21N Create Purchase Order (R4.6 onwards)
IP06 Display Maintenance Item ML81 Create Service Entry Sheet
IP10 Schedule Maintenance Plan MM03 Display Material
IP11 Change Maintenance Strategy QS42 Display Catalog
IP12 Display Maintenance Strategy MCI1 PMIS: Object Class Analysis
IP13 Strategy Package Sequence MCI2 PMIS: Manufacturer Analysis
IP14 Strategy Package Sequence MCI3 PMIS: Location Analysis
IP15 Maintenance Plan List Editing - Change MCI4 PMIS: Planner Group Analysis
IP16 Maintenance Plan List Editing - Display MCI5 PMIS: Damage Analysis
IP17 Maintenance Item List Editing - Change MCI6 PMIS: Object Statistics
IP18 Maintenance Item List Editing - Display MCI7 PMIS: Breakdown Analysis
IP19 Maintenance Scheduling Overview Graphic

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6. Glossary
▪ Master Inspection Characteristics (MIC)
Master Inspection Characteristics signifies the characteristics of a material/Test
Equipment which will be observed during Inspection and the value of the same Test
recorded. For example: In this document we have considered the Test Equipment as a
Pressure Gauge whose key Inspection characteristic (MIC) would be Pressure reading
(would include Lower Reading, Upper Reading, Mean Reading if relevant).
Master Inspection Characteristics for Test Equipment management should preferably be
maintained as master data in SAP to facilitate accurate and seamless Calibration
Management process.

▪ Inspection type
Inspection type is a term introduced from QM module. It simply refers to the source of
Inspection. For example: If the source of Quality inspection is Goods receipt, Inspection
type is 01, if it is Production receipt it is 04, for Test Equipment Calibration work it is 14
and so on. For Calibration (Test Equipment Management) scenario, inspection type 14
should be used, as demonstrated in this document.

▪ Inspection point:
Inspection points are used to identify objects under inspection. For example – Inspection
point to identify samples, Inspection point to identify Maintenance objects, freely
defined Inspection points and so on.

Inspection point 300 is used to identify Equipments for Calibration in Standard SAP system.
A configuration snapshot below:

▪ Inspection Lot

Inspection Lots are generated on a sample based on a specific trigger or manually. In

calibration work, Inspection Lot on a Test Equipment (using Fixed sample of quantity 1)
would be created when a Calibration work order is released. Inspection Lot No
14xxxxxxxx.. will be generated with Inspection type as 14.

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