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Process Excellence

SAP PLANT MAINTENANCE

Your Trusted IT Partner

SAP
R/3 ERP
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Accounting Area
Financial accounting (FI)
Controlling (CO)
Asset Accounting (FI AA)
Human Resources
HR
Logistics
Production Planning (PP)
Materials Management
(MM)
Sales and Distribution (SD)
Quality Management (QM)
Service Management (SM)

SAP
Organizational
Structure
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PM
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Overview
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Plant Maintenance Introduction
Plant Maintenance Organization
Technical Objects
Break Down Maintenance
Corrective Maintenance
Refurbishment Of Spare Parts
Preventive Maintenance
Work Clearance Management

Plant Maintenance Introduction

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SAP Plant Maintenance automates the process

of performing facility repair and maintenance
requests.
For example,. SAP records a problem that is
reported, labor and materials are planned,
costs are recorded, and then costs are settled
Plant Maintenance operates the overall
maintenance business processes and functions
allows a maintenance organization to:
Identify, document, and correct failures and
degradations of any assets for which they have
responsibility.

Plant
Maintenance
Process
Flow
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Plant
Maintenance
Process
Flow
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PM Process Flow

Notification

Maintenance Order
Plan
Control
Schedule
Execute
Complete

Plant
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Overview

Plant Maintenance Organization

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Plant Maintenance Organization

1) Overview of Processes and Available Solutions
Lifecycle of technical Asset
Investment Planning
Projects Definition
Selection of Vendor
Plant Maintenance
External Procurement
shutdown

Plant Maintenance Organization

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Plant Maintenance Organization

Master Data

Characteristics

Cost Records

Classes

Bill of Material

Cost Center
Tasks List

Equipment/Functi
onal Locations

Maintenance
Work Centers

Maintenance
Strategies

Planning
Maintenance
Notifications

Order Processing
Material
Reservation

Material Issue

Maintenance
Plans

Maintenance
Order

Purchase
Requisition

Capacity Load

Time
Conformation

Purchase Order
/Release Order

Goods
Receipt/Invoice
Receipt

Plant Maintenance Organization

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2) User Interface
Various methods that user connects to SAP
Power User
Sporadic User
3) Organizational Levels In Plant Maintenance
Depending on the Company Structure
Maintenance
planning is either of following type
Plant-Based (Decentralized)
Cross-Plant (Centralized)

Plant Maintenance Organization

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3) Organizational Levels In Plant Maintenance
Analyze Existing Company Structure
Define Maintenance Plants/Planning Plants
Assign Planning Plant/Work Center
Maintenance planner groups are assigned to
planning plants
Maintenance work centers are assigned to
maintenance plant

Plant
Based
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Plant Based Organizational Structure

Plant Maintenance Organization

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Maintenance Plant & Planning Plant
The plant, at which the operational
systems of a company are installed, is
called the maintenance plant.
If the maintenance work is planned at this
plant, the maintenance plant is also the
maintenance planning plant.
A maintenance planning plant is the
organizational unit in which maintenance
requirements are planned.

Plant
Maintenance
Organization
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Maintenance Planning Plant Structure

Plant Maintenance Organization

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Planner Group
The planners within a maintenance
planning plant are defined by maintenance
planner groups.
The units of capacity in Plant Maintenance
are managed as maintenance work
centres in the PM system.
The maintenance work centres are
usually assigned to the maintenance
planning plant.

Work
Centers
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Work center is an organizational unit where work is
carried out.
Ex: Machine, Group of machines or group of
persons.
Work centres belong to the master data in PM and
provide the capacity required to perform a task.
The basic data contains general data such as work
centre category, description, responsibility, and
usage
Work centers can be linked to:
Cost Centers, Positions, People

Work
Centers
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Functions:
Costing : To determine the costs of an
internal activity by a product unit
Scheduling : To determine the dates
when operations should be performed.
Capacity Planning : The capacity
requirements for the operations in the
orders are determined

Technical Objects

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Technical Objects
1) Functional Locations
Functional locations are elements of a technical structure . We
create Functional Structures if we want to represent systems or
operational structures within our company according to
functionality.
Create functional locations hierarchically, and can also structure
them based on the following criteria:
Spatial
Ex: Buildings.
Technical Ex: Press or Press Hydraulics
Process-related Ex: Polymerization,.

Functional Location Creation

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Functional
Structure
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Functional Locations

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Functional
Structure
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Functional Locations
The main Aim of creating Functional Locations is to Structure a technical
System or building into units that are relevant to Plant maintenance.

Functional
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Structure Indicator
The identification for functional locations is
created using the structure indicator. The structure
indicator consists of two input fields:
Edit mask : The edit mask is used to control which
characters may be used for identification (letters,
numbers, or both) and how these characters are
grouped together or split.
Hierarchy levels: The hierarchy levels are used to
define which level ends at which character and how
many hierarchy levels the structure may contain.

Functional
Structure
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Functional Locations
A functional location can be identified using a maximum of 40 characters (=
maximum length of the edit mask).

Equipment
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2) Equipment
A piece of equipment could be part of
bigger technical structures or independent
Piece of equipment is usually represented
as single object(Ex: Pumps, motors,
vehicle) for which maintenance tasks
should be performed.

Equipment
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Create an equipmentmasterrecord for a
technical objectif: You need to manage
individual data for theobject
Breakdown, prepared orpreventive
maintenancetask are required for
anobjectand must be recorded
Technical data for thisobjectmust be collected
and evaluated over long periods of time
The costs of maintenance tasks for
thisobjectare tobe monitored
Record the usage time of thisobjectat
functional locations

Purpose
of Equipment
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Functional Locations
The time-based data can be used to monitora piece ofequipment
dynamically, that is, track changes to the equipment over a specific period
of time.

Equipment
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2) Equipment
This role contains all the functions that you
require to process equipment.
Equipment Activities in Plant Maintenance (PM)
Creating a piece of equipment (generally, as
production resource/tool, fleet object)
Collective entry for equipment
Changing a piece of equipment
Data transfer from equipment
Taking up data transfer

Bill
Of Material
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Functional Locations

Bills of material are used for different purposes.

The usage depends on the enterprise area

Bill
Of Material
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3) BOM
The Production Bill of Materials
represents a finished product (parent )made
up of different inventory components
(children). During the production process,
you turn the components into the finished
product.
Components in the production bill of
materials are physical items (for example a
screw, a wooden board, a measured quantity
of lubricant or paint), or virtual objects (one
work hour)

Bill
Of Material
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3) BOM
The engineering/designbill of
materialincludes all theelements of the
product (from an engineering viewpoint)
and contains the technical data. It is usually
not dependent on the order.
The costingbill of materialreproduces
the product structure and forms the basis
for automatic determination of the material
usage costs for a product. Items that are
not relevant for costing are not included in
thisbill of material.

Bill
Of Material
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3)BOM
The maintenancebill of materialhas three
important functions:
It only contains items relevant to Plant
Maintenance.
Structuring of the object: The structure of an object
should be displayed as clearly as possible from a
maintenance viewpoint.
Spare parts planning in the order: If abill of
materialexists for a technical object, it can be used
during the planning process of a maintenance order for
the purpose of spare parts identification and planning.
Spare parts planning in the task list: Spare parts
can be planned in the task list based on abill of material

Bill
Of Material
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3)BOM
Instead of a uniform bill of material, these
areas use "their own" bill of material with
area-specific data (for example,
production).
They only evaluate bills of material
containing area-specific data. This results
in a targeted bill of material explosion,
whereby only the area-specific data is
made available.

Bill
Of Material
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3) BOM
Categories of BOMs are
Material BOM
Equipment BOM
Functional Location BOM
A material BOM is abill of materialthat is
first created for a material independently
of a technicalobject. To do this, material
creation is must.
Create a material BOM for the material

Bill
Of Material
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Functional Locations

Break
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Break Down Maintenance
Using this business process we can report,
perform, and document maintenance tasks
that arise suddenly.
All the resources used, costs, and technical
details of the maintenance task are recorded
centrally and can then be evaluated.
Usually this process is relevant if a technical
asset exhibits a defect, for example, if a
pump is leaking or a printer is not printing
properly.

Break
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Diverse employees can create a
maintenance notification to report the
defect.
The responsible maintenance technician
receives these notifications in his or her
work list and makes the necessary repairs.
Process Flow
1.Notification & Scheduling
2. Execution
3. Completion

Break
Maintenance
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Break Down Maintenance Flow

Break Down Maintenance

Break
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Create / process notification

Generate work list for notifications
Create / process order
Confirm time
Modify technical object structure
Process Execution
complete order

Refurbishment
Of Spare
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Refurbishment of spare parts:
In a company ,Defective or warn-out spare parts in
storage should be refurbished.

Refurbishment Process
Pre Requisites for Refurbishment in Material Master
Separate Evaluation
Refurbishment Order
Check the effects of refurbishments on stock value

Refurbishment
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Break Down Maintenance

Refurbishment
Of Spare
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titleParts
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Refurbishment of spare parts:
During the refurbishment process, equipment is
maintained by a team of maintenance planners,
maintenance technicians, and store persons.
After a maintenance technician has determined
and replaced the defective equipment, the
maintenance planner posts the defective item
to stock
After planning has been posted, the
maintenance planner creates and releases a
refurbishment order for the given items.

Refurbishment
Of Spare
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titleParts
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Refurbishment of spare parts:
Calculated the time and material resources
are neede for the refurbishment.
The order is conformed and Completed.

The stock value changes dynamically

according to the condition of the items, with
the price of a refurbished item covering all
internal and external material and labour
costs spent on refurbishing.

Preventive
Maintenance
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Preventive Maintenance
Preventive maintenance work is performed to
ensure optimal operation of equipment & avoid
costly unplanned equipment failure or shutdown.
To keep down times and maintenance costs
minimum, the technical systems are inspected
and maintained regularly
Preventive Maintenance Can be followed by 3
Factors
Time Based
Performance Based
Condition based

Preventive
Maintenance
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Preventive Maintenance
Time Based
Intime-based preventive
maintenance,the maintenance tasks are
planned and performed depending on the
time-dependent intervals determined. (Ex
,Every 6 months)
Performance-Based (Performance)
This preventive maintenance,tasks are
triggered after a specific performance level
has been reached
(Ex, Every 10,000 kms)

Preventive
Maintenance
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Preventive Maintenance
Condition Based
If the service life is exhausted or if the
asset is no longer in good enough
condition to perform its service to the
required quality
Then the service life must be restored
through maintenance or repair work.
These maintenance tasks are generated
and performed based on a certain asset
condition.

Preventive
Maintenance
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Preventive Maintenance

Break Down Maintenance

Preventive
Maintenance
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Task Lists
In the company, all inspection and
maintenance tasks that must be performed at
regular intervals are defined in maintenance
task lists.
Task list header data
Maintenance Planning
Single Cycle Plan (Same activity at
regular intervals)
Strategy (Maintenance work performed in
different cycles)
Maintenance strategy

Preventive
Maintenance
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Preventive Maintenance

Process in Detail
Create / process notification
Generate work list for notifications
Create / process order
Plan and schedule order
Perform work clearance management
Confirm time
Perform evaluations in plant maintenance
information system (PMIS)

Corrective
Maintenance
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Corrective Maintenance
Maintenance actions carried out to restore a
defective item to a specified condition
5 Phases of corrective Maintenance
Entering Requirement(Notification)
Planning Orders with Operations and Materials
(Planning)
Monitoring the cost (Control)
Performing the tasks(Execution)
Completing the Order and Notifications.
(Completion)

Corrective
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Corrective Maintenance

Break Down Maintenance

Corrective
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Corrective Maintenance

Corrective
Maintenance
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Corrective Maintenance
5 Phases of corrective Maintenance
Entering Requirement(Notification)
Planning Orders with Operations and
Materials (Planning)
Monitoring the cost (Control)
Performing the tasks(Execution)
Completing the Order and Notifications.
(Completion)

Corrective
Maintenance
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Corrective Maintenance
Notification: is the technical object
contains the description about the
malfunction or requirement
Malfunctions and other requirements are
recorded in notification, notifications can be
accessed and processed via a list
Planning : In this phase orders are created
and planned on the basis of the reported
requirements. Planning compasses the Work
to be performed , and the material required.

Corrective
Maintenance
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Corrective Maintenance
Control: In this phase order runs through
the different phases such as material
availability check, capacity planning.
Execution: Order is executed in this phase,
Required material for the order is
withdrawn.
Completion: Technical Conformation and
Technical completion.

Work
Management
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Work Clearance Management
This business process to enforce all safety
measures that must be enforced before
inspections, repairs, or preventive
maintenance work are performed.
Maintenance Workers operate in a dangerous
Environment(Ex: High Voltage, Radio Activity).
The WCM component helps company to
control and monitor safety measures.
Helps to ensure and secure working
conditions for plant maintenance employees.

Work
Clearance
Management
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Work Clearance Management

Break Down Maintenance

Work Clearance Management is integrated into the Plant

Maintenance (PM) component

Work
Clearance
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WCM Process Flow (1)
Order

Work Clearance
Application

Create Order

Plan Order/ Request

Tag Out

Specify Object
containing
Tag
Break Down Maintenance
out/Lockout

Work Clearance
Document

Work Clearance
Document

Approve and Perform

Tag out/Lockout

Work
Management
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Work Clearance Management
Lockout-Tag out (LOTO)orlock and
tagis a safety procedure which is used to
ensure that dangerous machines are
properly shut off and not started up again
prior to the completion of maintenance or
servicing work
Work Clearance Document: This
document contains a detailed description of
lockout / tag out .

Work
Clearance
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WCM Process Flow (2)
Release Order

Work Clearance
Application

Work Clearance
Document

Release Order
Determined
Completing Tagging

Perform Un-tagging

Break Down Maintenance

Order
Completion

Technically
Completing Order

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QUERIES ?

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