Why Plant Maintenance (also known as EAM)

Plant maintenance usually refers to the methods, strategies, and practices used to keep an industrial factory
running efficiently. This can include anything from regular checks of equipment to make sure they are
functioning properly, to cleaning garbage bins and toilets. The general aim of plant maintenance is to create
a productive working environment that is also safe for workers.

Since there are many different types of plants and factories, the ways to maintain these facilities often vary.
For example, a steel mill will have different machinery than a food processing plant. This means that each
place of business generally has its own maintenance plan, tailored to its particularities. A maintenance plan
can include scheduling times for equipment checkups, trouble-shooting, and general clean-up.

Most plants employ their own maintenance staff. This can include workers such as on-site engineers, whose
job is to make sure that machines continue to operate effectively. This is an especially important for plants
that use equipment designed for assembly lines, since a stoppage of the line can be financially damaging.
 PM Hierarchy
Financial Component (FI) — This component determines the financial rules for reporting
outside of the enterprise, most notably for the Internal Revenue Service and Securities and
Exchange Commission for companies, both of whom have very specific reporting and monetary
control procedures that are common to all publically traded corporations.

Controlling Component (CO) —This component will create very specific groupings of reporting
and controls that align with business units and specialties that not only allow for cost tracking
segregation, but also allow the PM component user to partition business unit commonalities for
maintenance and reliability information.

The Maintenance Plant

The Maintenance Plant is the representation of the asset of production work centers (labor or
equipment) as well as the process-based representation of the equipment assigned to that plant.
The process-based hierarchy utilizes Functional Locations to segregate the process locations to
align with plant reporting and control parameters.

The Planning Plant

The Planning Plant is the maintenance labor service arm of the plant maintenance component.
The Planning Plant includes the planner groups, the designation of the planning function by area,
crafts, or group. Also included are the Maintenance Work Centers, also used to segregate labor
by groups, area, or crafts. The planning plant becomes the interface to the Human Resource
component (HR) for labor resources and the Materials Management (MM) component for parts.

Human Resources (HR) —The key functionalities include payroll management, capacity planning,
and skills management.

Materials Management (MM) — The key functionalities of this component include inventory
management of the storeroom ( including Materials Resource Planning functionality which
streamlines the parts replenishment process) as well as the purchase of outside materials and
services required for maintenance of the equipment
 PM Process
Maintenance Plan — Contains the scheduling parameters for time and condition-based
preventive maintenance routes.

Task List — Contains the work steps, labor, and materials documentation to execute the
maintenance plan, as well as being available to corrective work orders.

Notification — Contains the description of the reliability opportunity and details the symptoms
of the initial reliability issue. Upon completion of the corrective work order, the notification
receives and reports the failure codes for reliability history.

Maintenance Order — Contains the administrative and planning information to execute a

maintenance activity, either preventive or corrective. The maintenance order is the cost tracking
entity of the PM component.

Maintenance Order Operations — Contains the detailed work steps executed under the
umbrella of the maintenance work order. The operations contain the planned labor work totals
and materials (components). The order operations utilize the labor and parts resources provided
by the SAP HR and MM components.

Confirmations — Contain the actual totals of technician work and materials used. The
confirmations have links back to both the orders for further detailing of the repair processes and
to the notification for recording the failure codes and data for reliability history.

The basic design of SAP PM is focused on relying heavily on equipment reliability success through utilizing the preventive maintenance capability of the
system. Provisions are made for reactive work, and building histories to serve as a catalyst to improve, but as with all maintenance goals, reducing the
emergencies is the goal. With that in mind, the value proposition in SAP PM is rooted in the belief that maintenance work should strive to be proactive,
not reactive.
 PM Process: Money Trail
Company Code — The designation of the company the maintenance plant is attached to. Every
piece of equipment within this specific company has this coding assigned to the equipment
master.
Business Area — Should the company decide to segregate business units within the company,
the business area designations can be utilized. The designations do not have to be plant specific,
and for those plants with multiple business units on one site, this not only allows for accounting
by business, but views into similar business units in other plants for similar processes.
Controlling Area / Controlling Code — The controlling area is the master financial rules set at
the client level. The controlling code is the company unique control rules if multiple companies
exist on the client that uses different rules.
Cost Center — Within the Plant Maintenance component, the cost center is best known as the
typically final repository of the work order cost accumulation. Cost Centers are assigned to the
Business Area.

Every work order requires labor and/or material costs. Once the work is complete, the order
settles to a cost center that is designated by the equipment on which the work is assigned. The
net sum of the work order cost is zero after settlement, making the order only a transitional cost
element. The cost centers totals are then linked into combinations of business area, plant, or
company totals to provide the maintenance cost reporting and accountability the company
requires to manage the business effectively.

PM is designed to keep the equipment running, but is also accountable to the rest of the company for cost and information accountability.
 Major Integration

Sender Activity
Function Type
Notification PM Work Cost Center
Location
Center
Receiver
Cost Center

Maintenance
Equipment Order Header
Plan
GL Fixed
Account Asset Operation -
Internal
Shutdown
Operation -
Service
BOM Spare
Service Master
Components

Costs Material Master

PM Business Process
Corrective Non Routine
Planned Un-scheduled maintenance work which is planned in advance.
Maintenance

Routine HSEC
Preventive Planned Scheduled maintenance activities for Health, Safety Environment and General
Maintenance /Maintenance maintenance work
Order

Breakdown Maintenance Maintenance Orders which are created for unplanned activities such as work
order/Notification recorded on operator shifts or for breakdowns.
Maintenance Unplanned

Refurbishment Refurbishment
order (Only serial
Used for Rotable & Non-Rotable Refurbishment activates.
of spare parts no's)

Project Projects and Seldomly used.

Modification Maint
Maintenance Order

Used to keep track of Rotables lent out or borrowed between mining

Other Rotables on Loan companies.
Maintenance
PM- Corrective /Planned Maint..
In Corrective Maintenance, you correct a
malfunction or a machine failure by
raising a notification in the system. The
work order is received by the technician
who enters the information. An
authorized person in the PM system
approves and completes the work as per
the work order
PM- Preventive /
Planned Maint..
PM- Breakdown /Unplanned Maint..
Breakdown Maintenance is carried out
when your equipment has a breakdown
and is not working. In Breakdown
maintenance, production is affected
PM- Refurbishment/ Rotable Repair
Mining equipment maintenance is a necessary
part of mining processing and production. Mining
equipment repair is also one of the components
of running a successful operation. Mining
equipment manufacturers understand that
maintenance and repair services should be
provided by the best service providers available.
Mining equipment maintenance requires skill
and experience to provide the top quality service
to manufacturers in the industry
“Refurbishment” Business Process
PM- Project/ Modification Order
Use of PM-PS integration points
• WBS elements are linked to the FL on
which the project is performed
• Project activities for internal resources
are planned with a control key that allows
“capacity requirement”
• PM order affectation to projects leads to
an automatic replacement of the activity
control key (no capacity req.)
• Work Centers usage must be changed
from “Maintenance” usage to “All task list
types” usage