Introduction “Transforming the company through SAP”

The purposes of this Production workshop:

Provide you the conception of the model (role-out) and show you a global vision about the
Maintenance module in our company implemented before.

We have to transmit a new culture where we will have to be very disciplinated daily report, order
control and daily confirmations of the maintenance orders.

Accurate relationship in between cost centers and the functional locations.

 PROCESSES:

MAINTENANCE : PREDICTIVE / CORRECTIVE

1
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA MAINTENANCE

External These activities are

EXTRACT Spares Functional
Master data performed directly on
Basic Data 1 &2 locations
(Engineering BOM etc.) SAP.
MRP viewspare

Work center
Workers: Equipments
COST CENTER

Bill of
Work centers
material
BOM

Equipment
Operations
Work center SAP
MAINTENANCE Key changes:
Functional ORDERS - Add new parts
locations - Add new levels
Operations - Split the quantities
All master data is
Necessary for creating
Task list Production orders,
Operations comsuptions and to carry
Work center out all costs.
2
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA MAINTENANCE

These activities are
performed directly on
SAP.

1. Master data : Bill of Material.

BILL OF MATERIAL
Master data – Bill of material “Transforming the company through SAP”

 Bill of Material

 A list of materials for each set of maintenance is created.

•• The BOM will Xnnnnn as other positions X subsets.
•• The X subsets BOMs have positions as the corresponding spare parts.
Assignment in to Equipment (structure data)

Mechanical
elements

Lubricants

Electrical
Elements
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA MAINTENANCE

These activities are
performed directly on
SAP.

1. Master data :Production resources tools.

PRT: Tools
Master data – PRT: Equipment “Transforming the company through SAP”

 Production Resources Tools

 Tools, measuring equipment, etc.. used to perform the work of maintenance.

 Assign into The orders or routing directly , in this way the assign during generating orders preventive maintenance the allocation MAF's are
automatic done.

Tipe P: PRT

Lubricants

Electrical
Elements
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA MAINTENANCE

These activities are
performed directly on
SAP.

1. Master data : Technical location

TECHNICAL LOCATION
Master data – Functional Location “Transforming the company through SAP”

 Functional Location : General

• They define a functional area within a plant and that in turn contains equipments and sub-equipements basically.
• They have been coded as locations technical the sections and subsections of the factories in a very similar way the productive structure and cost centers.
A technical orders generic of maintenance are also directed into the function locations.

Equipement

Sub-
Equipment
Master data – Functional Location “Transforming the company through SAP”

 Functional Location: General

 Basically consists of a codification, description, operating status and a series of information regarding their
structure and organization, as well as a of the drawings and associated documentation.

Technical V202
Master data – Functional Location “Transforming the company through SAP”

 Functional Location: status

The system status, activate and deactivate depending on operations conducted on the technical location
•CRTE – Functional location created. INAC – Functional location de-activated. DLFL – Deletion Flag.
The user status can activate and deactivate manually.
•ACTI – F. Location On. (By default when you create). PARA- F. Location stop.
You can not create orders for functional locations with INAC or DLFL status.
• Releasing corrective maintenance orders, if the functional location is stopped (status PARA) will be created
directly suborders of Great Repair.
• Changing the user status of a section, automatically modifies of its subsections.
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA MAINTENANCE

These activities are
performed directly on
SAP.

1. Master data : Technical location

EQUIPMENT
Master data – Functional Location “Transforming the company through SAP”

 Equipment: General

Individual physical object on which maintenance tasks are performed.

• Can be installed in technical locations and may themselves be structured into sub-equipments.
• Function location are also objects to which maintenance orders specific are target.
Catégories:
A PRODUCTIVE EQUIPMENT
C SHOVEL EXCAVATOR
D TRAILER
M :MACHINES
P: TOOLING
Y INTERNAL VEHICLE
Z EXTERANL VEHICLE
Donnée Maitre– Nomenclature BOM “Transforming the company through SAP”

 Equipement: Structure

 From here you can do the assembly and disassembly of technical placements or higher devices.

 There are also a number of fields where it is possible to keep the information extracted
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA SHOP FLOOR

These activities are
performed directly on
SAP.

1. Master data maintenance: TASK LIST / KEY MODEL

TASK LIST
Master data – task list “Transforming the company through SAP”

 Task list / Key model

 S: society / G: Factory / P: Specialization: M (Mechanical) /NNNN: counter

 Here we are referencing a key with a text description in order to maintain the same
text description. Key could be a long text instruction (several operations).
Master data – task list “Transforming the company through SAP”

 Task list

 Here we are defining the operations related to the maintenance

- Task list for equipments

- Task list for tecnical location  Status : We use for the printed
- Task list for general instruction. ZPM009 transaction

R: brief frecuency
L: Normal , all data printed.
F: with page breaks
S: check the key text previous order in
order to avoid repation.

 System condition (installation

status) : We use for the great repairs

C: Constant
F: Fix
H: Kiln stop
L: Stop line.
M: Running.
P: Partial stop
Q: Machine stop
T: total stop.
Master data – task list “Transforming the company through SAP”

 Task list : overview

 Diferent operation (group counters) : strategy / Status

General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA SHOP FLOOR

These activities are
performed directly on
SAP.

1. Master data maintenance: Work centers

WORK CENTERS
Master data – Work center “Transforming the company through SAP”

 Work center

 Here there are defined the responsible of the orders execution. The groups of the
workers (internal or external) to perform maintenance tasks. Ex: Electrical lubrication

Work centers
V202
General Process – MAINTENANCE MASTER DATA “Transforming the company through SAP”

MASTER DATA SHOP FLOOR

These activities are
performed directly on
SAP.

1. Master data maintenance: Measure

Measure Points

Counters
Master data – Measure points / counters “Transforming the company through SAP”

 Measure points / counters

 Individual: reading a measuring point / counter is introduced individually.

 By list of input values: readings from multiple meters are introduced together.
 Records of measurement Measuring points associated with preventive orders: For
introduce readings from multiple points of measurement, by closing transaction orders
ZPM013 preventive maintenance.
Master data – Maintenace plans “Transforming the company through SAP”

 Parameters

Call horizon: ej 4 weeks cycle: 75% means it’s going to be

created 1 w before.
-100% : It’s created when it’s up
-0 %: we always we have the next order created

Shift factor late: % of delay must be taken into account

when planning the next order. Ex: 5 delayed days with 40%
=> 2 delay days to consider.
-0%: we do not consider delays
-100%: consider delay (base on cycle)

Call horizon: ej 4 weeks cycle: 75% means it’s going to be

created 1 w before.
-100% : It’s created when it’s up
-0 %: we always we have the next order created

Sched period : you should only set the scheduling period if

Frecuency <= 1 month > 1 month you want long-term planning.
Ship Factor Late : 0 100
Shift factor Early : 0 100 Fixed Planning <=1 M
Call horizont : 100 100 Is not taken into account the closure of the last order generated.
Complet Requir: √ Flexible Planning. > 1 M
It takes into account the closure of the last order generated the plan and its
technical closing date (CTEC)

Weekly reprogramming IP30 Maintenance Plans (Thursday 2:00)

Master data – Maintenace plans “Transforming the company through SAP”

 Parameters

New start Complete

Scheduled Called
Scheduled Complete
Manual Complete
Manual Called
Scheduled Hold
Save to Call

-The maintenance plan is not started

- The call is for a future date and will not generate by the plan until to
reach the trigger date.
-Take another date
-….
Master data – Maintenace plans “Transforming the company through SAP”

 Parameters

For jobs (plans) maintenance that are based on counters, the "Factors offset" must be 100% and the
"Tolerances" to 0% for both delay and advancement, and the "Horizon Opening" also 100%, so the
programming is done to overcome these counter, not on future estimates, which in many cases turn out to
be uncertain.