PM Overview New

Brief History of SAP
• 1972 Company started

• 1973 SAP R/1 launched
• 1977 First International Customers
• 1979 SAP R/2 solutions launched
• 1988 Company goes public in Germany
• 1992 SAP R/3, ECC6 launched
• S/4 Hana 1909, 2020
Brief History of SAP
• 1972 Company started

• 1977 First International Customers
• 1979 SAP R/2 solutions launched
• 1988 Company goes public in Germany
• 1996 CRM and SCM solutions launched
• 2004 Central components launched
• 2005 Central components with Netweaver
SAP R/3
• POWERFUL TOOL FOR Enterprise Resource
Planning
• TIGHTLY INTEGRATED SAP R/3 Application

Modules
• HIGHLY FLEXIBLE SAP R/3 Basis and

communication System
What is SAP R/3 ???
Systems
Applications
Products
In Data Processing
• R Stands for Real Time
• 3 Stands for - Three tier architecture
(Presentation, Application and Data Base)
• Presentation server is the front end
SAP R/3
SAP R/3 is an integrated system designed to

cover wide spectrum of business processes.
R - Real Time
3 - Tier
User Front-end
Database Server Application Server (GUI)
SAP R/3 : 3 Tier Architecture
The Presentation Layer

Those SAP R/3 software components that
specialize in interacting with end-users
form the Presentation Layer.
The Application Layer

specialize in processing business
applications form the Application Layer.
The Database Layer

specialize in the management , storage and
retrieval of data form the Database Layer
SAP R/3 : 3 Tier Architecture
Presentation Layer Application Layer Database Layer

components components components
reside in: reside in: reside in:
Presentation servers: Application servers: Database servers:

Systems capable of Specialized systems Specialized systems
providing a graphical multiple CPUs and with fast and large
interface. vast amounts of RAM. hard drives.
PM Overview
PM in SAP Environment
SD FI
Sales & Financial
Distribution Accounting
MM CO
Materials Controlling
Mgmt.
PP AM
R/3
Production Fixed Assets
SAP R/3
Planning Mgmt.
Integration
QM
Quality
Client / Server
ABAP PS
Project
ABAP/4
Mgmt. System
PM
Plant WF
Maintenance Workflow
HR IS
Human Industry
Resources Solutions
Overview
PM - Organization Structure
General organizational units
Client e.g. company
Plant e.g. production sites
Storage location e.g. spares storage
Location-related organizational units
Maintenance plant e.g. plant with technical system
Location e.g. area, buildings
Company area e.g. production area,

production engineer
Planning-related organization untis
Planning plant e.g. plant for maint. planning
PM planner groups e.g. foreman, work preparation
PM work centers e.g. mechanics, electricians
Organization
Sub-Modules of PM
Technical Object
Maintenance Processing
Preventive Maintenance
Information System
Sub-Modules
Technical Object
Technical Object Master Data
•Functional Location
•Equipment
•Bills of material
•Measuring Points & Counters
•Task List
Functional Location
Functional locations are the physical locations

of a technical object where equipment can be
installed and dismantled.
Functional Location
Functional Location
Criteria for Structuring Functional
Locations
location
technical
functional
Functional Location
Hierarchical Location Structures
Example 1 Example 2
Plant 0001
Asset C1
Asset 0001-S01 Area C1-M
Sub-area C1-M01
Sub-area 0001-S01-11 Function C1-M01-2
Sub-function C1-M01-2-A
Functional unit 0001-S01-11-M10 Item C1-M01-2-A-4
Functional Location
Structuring Rules
Example 1 XXXX-XNN-NN-XNN
Example 2 AN-ANN-N-X-X
Key:
A=alphabetic
N=numerical
X=alphanumerical
Functional Location
Representing an Operational Systems
Structure Using Functional Locations
C1
Clarification
plant
C1-M C1-B
Mechanical Biological
purification purification
C1-M01 C1-M02 C1-B01 C1-B02

Oil/fat Pumping Filtering
Sand trap trap station station
C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3 C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2
Sand Fat Filter
Reservoir Ventilator dredger Reservoir Ventilator dredger Pump 1 Pump 2 Ventilator cell
C1-B02-1A C1-B02-1B C1-B02-2A C1-B02-2B C1-B02-2C

Filtrate
Valve 1 Valve 2 Inlet layer Outlet
C1-B02-2A/1 C1-B02-2A/2 C1-B02-2C/1 C1-B02-2C/2

Valve 1 Valve 2 Valve 1 Valve 2
Functional Location
Equipment
Equipment is an individual object that is to be
maintained independently. It can be installed
and dismantled at functional locations.
• Equipment Types
•Equipment Code Numbering
•Material Code for Equipment
•Warranty Data
•Activating/De-activating
Equipment
Equipment
Contents of an Equipment Master
Record
Equipment master record
General data
Location data
PM data
Sales/distribution data
Partner Data
Serial Number
Equipment usage
Classification
Documents
Equipment
Equipment Hierarchy
Production
Functional locations
Installation
Equipment hierarchy
Equipment
Equipment
Equipment
Equipment
Maintenance Bill of Material
Bills of material are used to describe the structure of a technical object and to
alllocate spare parts for maintenance purposes.
BOMs for technical objects can be created individually for a specific technical
object or for a group of technical objects.
Level 0
Equipment
Level 1 Motor Shaft/ Gearbox Level 1
Level 2
Spare Spare Assembly Assembly
Spare Spare
Maintenance BOM
Structuring Technical Systems and
Equipment
FunctLocation
FunctLocation
hierarchy
FunctLocation
Installed
equipment
Equipment
Equipment
hierarchy
Equipment
Equipment
BOM
Assembly
Assembly
BOM
Spare
Maintenance BOM
Technical Objects
Measuring Point & Counter

You use this component to enter measurement and counter readings for Technical
Objects. This can be of use in the following situations:
You want to document the condition of a technical object at a particular point in
time.
Documenting the condition of a particular object is of great importance in cases
where detailed records regarding the correct condition have to be kept for legal
reasons. This could involve critical values recorded for environmental protection
purposes, hazardous working areas that are monitored for health and safety
reasons, the condition of equipment in hospitals (intensive care units), as well as
measurements of emissions and pollution for objects of all types.
Measuring Point
Task List
Integration
Using maintenance task lists, you can reduce the time
required to create maintenance orders and
maintenance items as you can refer back to the
operations and sequences already entered in the
maintenance task list.
Moreover, you can include inspection characteristics
from the Quality Management module in maintenance
task lists.
Task List
Maintenance Task Lists
To standardize work flows
To plan maintenance orders more

Why? effectively
To create maintenance plans more

quickly
Task List
Task Lists in Plant Maintenance
Sequence of individual maintenance activities

Execution at regular intervals
What ?
Simplified maintenance planning with repeated use
of operation sequences
Work steps (operation)
Maintenance work centers

Contents ?
Times
Material components
Regular maintenance (servicing and inspection)

Usage ?
Ongoing maintenance (planned repairs)
Task List
Maintenance Task List Types
E Equipment task list
A General task list
Task List
Elements of a Maintenance Task List
Group ( IH Pumps )
Inspection
Function checks
Mechanical
repairs
Maintenance task lists
Operations
Sub- operations
Material
Maintenance packages
Task List
PM Task List Groups
Motors: general overhead
Pumps: inspection
Mechanical repairs
Pumps: mechanical repairs group
Counter
01 Maintenance
tasks when
damage x occurs
02 Maintenance
tasks when
damage y occurs
Maintenance Task List Structure
Strategy,
maintenance
Task list header planning
group, work
center,
equipment
Work center, description, time,
Operation control key, external processing
data, maintenance packages
Operation, time, work center,

Sub-operation description, control key
Quantity, BOM item,

Material item category, quantity unit
Maintenance
Quantity, category
resources
Maintenance
Allocation of maintenance packages
packages
Task List
Operations
External Processing
Internal Processing
Control key: PM02 ....
Control key: PM01 .... Contents: vendor
Contents: work center purchasing group

reference key
net price
length of work
purchasing
operation duration
wage data organization
info record
Task List
Maintenance Task Lists - Sub-
Operations
Task List Group 4711 Diesel Engine Service
Op. Sub-op. WrkCtr Description
0010 ME Clean engine

0010 0010 EL Disconnect electric's
0010 0020 ME Clean engine
0010 0030 EL Reconnect electric's
0020 ME Clean fuel pump

0030 ME Change fuel filter
0040 ME Change oil

0040 0010 ME Remove oil drainage screw
0040 0020 ME Remove preliminary filter case
0040 0030 ME Change paper filter
0040 0040 ME Clean valve bonnet
0040 0050 ME Clean and replace screw
0040 0060 ME Refill oil
0050 ME Check oil level
Task List
Material Components and Operations
BOM
PM Task List
Operation 10
Item 10
Operation 20 Sub-item 1
Sub-item 2
Item 20
Operation 30
Item 30
Sub-item 1
Operation 40
Sub-item 2
Sub-item 3
Task List
WHY
??
Purpose
Preventive maintenance
should maintain the • Legal requirements
high availability of • Customer requirements

• ( for example, automobile industry )
technical systems, for • Reduction of system malfunctions
example, production • Reduction of system restart costs
plants, in the long • Extension of system life
term. •
• Increased productivity
• Better capacity load control
• Reduction of repair costs
Preventive Maintenance: Categories
Preventive
Maintenance
Time-Based Performance-Based Condition-Based
Temperature
Pressure
Thickness
WHAT?
WHEN? Task lists
Time- or counter-based
strategies
Maintenance
plan
- Single cycle
- Strategy
- Multiple counters
Order/
Notification
Order/
Notification
Order/
Notification
Schedule plan
WHERE?
WHAT?
WHEN? Task lists
Time- or counter-based
strategies
Maintenance
plan
- Single cycle
- Strategy
- Multiple counters
Order/
Notification
Order/
Notification
Order/
Notification
Schedule plan
WHERE?
Preventive Maintenance Processing
Maintenance
plan Order/
Notification
Order/
Notification
Order/
Notification
Scheduling
Dispatching
Worklist Maintenance
Execution
Maintenance Plan Structure
Maintenance plan
Maintenance Maintenance
Due date forecast
strategy schedule
03.04.04
03.06.04
Maintenance items 03.08.04
Maintenance orders
Maintenance
task list
Maintenance Planning
Maintenance Plan and Maintenance
Strategy
Maintenance Plan
Strategy " STRATXY "
STRATXY
Package 1
every 2 weeks item
...
Package 2
...
monthly
Package 3
Operation List
Vorgangsliste
half-yearly
Routine inspection
Package 4 Pressure check

every 2 years General overhaul
Maintenance Item - Contents and
Structure
Maintenance Item
Strategy
Item data Description Object list
Primary object
FunctLocation
Work center Equipment
Planning data Order type Assembly
Planner group
Type
Task list data
Group Operation List
Maintenance plan data Operations

Task list
Location / account
assignment data
Maintenance Item and Maintenance
Task List
Maint. Task List
Maintenance Item
General data:
Item data
Task list : A
Group: 200174
Planning data Group counter : 1
PM task list data
1M 4M 6M
Operation data:
Type: A
Group: 200 174 Operation 10: 1M 4M
Group counter: 1 Operation 20: 1M 4M
Operation 30: 6M
Operation 40: 1M 4M
Maintenance plan data

Maintenance Plan
Maintenance Plan
Maintenance schedule
Scheduling object
Strategy
Start / last confirmation
Maintenance item
10
10
20
30
40
Scheduling Functions
Function Details Required
Date on which maintenance

was to/is to begin
Restart
Last actual date
Start in cycle Last maintenance package
Schedule Last actual date
Manual call Next planned date
Maintenance package
to be performed
Cross-plant Maintenance Processing
Location Planning Execution
Plant 0002 Plant 0001 Plant 0004
Planning Workshop 1
Maintenance maintenance
requirements tasks
Workshop 2
Material stock Workshop 3

Plant 0003
Maintenance
requirements
Maintenance processing
• Break Down Maintenance
• Refurbishment Process
Break Down Maintenance
Features
Maintenance processing can be divided into the
following three areas:
Description of the Maintenance

object condition Notification
Execution of Maintenance
maintenance order
tasks
Completion of Maintenance
maintenance History
tasks
Basic Steps in Maintenance Processing
Plant PM Planning PM Workshop
2
4
Malfunction, error 3
5
Order
Request Creating the order
Requesting a
Activity Planning the task
maintenance Execution
Task who
material issue
1 when, for how
procuring PRT’s
long
work steps
what steps
PM Notification account
what assignment
when resources
where
tech. information 7
breakdown Completion
6
Tech. information
Completion
breakdown confirmatio
causes n
objects affected
activities
8 Completion
PM History
Definition of a Maintenance Notification
for describing the condition of a maintenance object

and the malfunction in particular
Malfunction report
for describing a maintenance activity that has already

been performed - purely technical documentation
Activity report
for requesting a maintenance activity/task
Maintenance request
Notification
Structure of Maintenance Notification
date/time/reported by
Notification description
PM object: functional location
equipment
assembly
location data
account assignment data
bre/availaakdownbility data
Damage, Cause & Object

Notification
Text
items
activity
Activities
performed by
Maintenance dates
tasks task description
Maintenance Order Functions
Capacity planning
Materials
Operations BOM
Work centers Task list
Object list Costs
External
Objects
processing
Planning
Shop papers
Material issue
Purchase orders
Execution
Goods receipt
Invoice receipt
Completion confirmation
Cost center
Asset
Settlement
Project
Order
Maintenance order
Structure of the Maintenance Order
E.g. order type, dates,
plant, primary object,
Order header priority, description,
location data,
account assignment
equipments (and assembly),
functional
Object list
locations, maintenance
Notification
E.g. work center, control
key,
Operation description, standard
time, activity
type, wage details
Sub-operation
E.g. quantity,
unit, storage,
Material location,
availability,
Maintenance item category

resources
Settlement rule
Location/account
assignment
Costs
Maintenance order
Cost Display in the Maintenance Order
Maintenance Order Costs
Internal Processing Internal processing: Rs 300

Op. 10: ME 3hrs.
Op. 20: EL 1hrs.
External Processing
Text External processing : Rs 75
Op. 30: External 1hrs.
Stock material: Rs 200

Stock material
2 pcs. Material ABC
Non-stock-material Non-stock-material: Rs 300

2 pcs. Material XYZ
Total: Rs 875
Maintenance order
Order Costs
Maintenance Order
Standard cost estimate

Planned costs
Actual costs Actual costs
Internal Operation Capacity load Job-time confirmation
StockText
material Reservation Goods issue
Non-stock material Purchase Order Goods receipt/

Invoice receipt
External Operation Purchase Order Invoices
Planned values Actual costs

Open item + Open item -
Maintenance order
Releasing an Order
Reservation effective,
material issue possible
Shop papers can be printed
Completion confirmation possible
Goods movement possible
Maintenance order
External Procurement Processing in the
PM Order
PM Order Purchasing Invoice
Verication
Allocation of Purchase
non-stock material requisition
Purchase order
Goods receipt
Invoice receipt
Purchase order
value
Cost of non-stock
materials
Difference between order value and invoice value
Maintenance order
Material Issue
Planned issue of material
Unplanned issue of material
Reversal
Maintenance order
Completion Confirmation
Completion confirmation
of time required for job
Technical completion
confirmation
Maintenance order
Job-Time Completion Confirmation
Entry Completion confirmation

Operation list
Scope Partial confirmation

Final confirmation
Cancellation option
Maintenance order
Technical Completion Confirmation
Cause of Damage
Object damage locations Items
Maintenance tasks
Activities
Downtimes Time from/to

Downtime duration
System availability Before malfunction

After malfunction
After maintenance task
Defect classification
Maintenance order
External Processing
Why ?
capacity situation
specialist training required
cost comparison
How ?
control key
Maintenance order
Scope of External Processing
Individual Operations
PM Order Purchase
requisition
Op. 10 PM02
Op. 20 PM01
Purchase
Sup-op. 20 10 PM01 requisition
Sub-op. 20 20 PM02
Op. 30 PM01
Complete Order
PM Order
Purchase
requisition
Op. 10 PM02
Maintenance order
External Processing Flow
PM Order Actual costs
Job-time
Op. 10: Internal processing confirmation
Op. 20: External processing Purchase

requisition
Purchase
order
Activity confirmation
Actual costs
Goods receipt
Invoice receipt
Maintenance order
Order Settlement - Receiver Category
Cost
Center
Asset
Project
Order
Maintenance order
Settling a PM Order
PM Order 100341
Reference Funct. location
object: C1-B01
Cost center 511

Settlement Cost center 511
- PM Order
Text Text $1200
100341
Object list
- Equipment 05P1234 -...
- Equipment A4321
Actual costs: $1200
- Equipment WZ-12-01
Maintenance order
Completion Confirmation
Logistics Plant maintenance Maintenance processing
Compl. confirmation Order operations

With Compl. Conf. No
With operation list
Display
Cancel
Maintenance order
Refurbishment Process
Refurbish Equipment
Dismantle
Equipment
Re-install
Equipment
Order Re-stock
Equipment
Issue
Equipment
0010 Refurbish pump

0020 Settle order
Stock
Refurbish Equipment
Dismantle
Equipment
Re-install
Equipment
Order Re-stock
Equipment
Issue
Equipment
0010 Refurbish pump

0020 Settle order
Stock
Refurbishment
Dismantling of faulty equipments and return to
warehouse for refurbishment
Material
condition-based valuation
Valuation type Valuation type Valuation type

C1 (new) C2 (refurbished) C3 (damaged)
$ 3000 $ 2500 $ 200
Material with condition-based value linked to the equipment is used to monitor

availability of stock in inventory management
Refurbish Equipment
Dismantle
Equipment
Re-install
Equipment
Order Re-stock
Equipment
Issue
Equipment
0010 Refurbish pump

0020 Settle order
Stock
Refurbishment
Dismantling of faulty equipments and return to
warehouse for refurbishment
Material
condition-based valuation
Valuation type Valuation type Valuation type

C1 (new) C2 (refurbished) C3 (damaged)
$ 3000 $ 2500 $ 200
Material with condition-based value linked to the equipment is used to monitor

availability of stock in inventory management
Refurbishment Process:
Advantages
 Completion of the life cycle of a

technical asset
 Uniqueness through serialization
 Life cycle trading of equipment
Maintenance History
Purpose
When managing technical systems, you not only
want to document and support the planning of
maintenance processing, you also want long-term
verification documents in the form of a maintenance
history.
Implementation Considerations
A long-term maintenance history (PM history) is
important for the following reasons:
 Recording maintenance activities
 Investing in replacements
• Repetitive planning
Maintenance History
PM Information System
Information Systems
Purpose
The Plant Maintenance Information System can be used at a variety of levels in
the decision-making process as an instrument for monitoring, controlling and
planning your business operations.
The Plant Maintenance Information System allows you to evaluate breakdown
behavior, or the maintenance tasks of a technical system or machine. It is also
possible to analyze the costs incurred or the party responsible for the
maintenance tasks and the exact activities that have been performed. It is used
in:
• Reporting
•Standard
•Customised
•Business Warehouse
Info. System
Plant maintenance Cycle
Functional Equipment Condition
Preventive Shut Down
Location Masters Based
Maintenance
Integration
Maintenance with
Settlement Order Notification Projects
of Order Closing Closure
Analytics
Functional Lo Equipment Condition
cation Preventive Shut Down
Masters Based Maintenance
Maintenance
Maintenance
Integration
Maintenance with
Analytics
Structuring of the Technical Assets

Hierarchical Structures
Functional Equipment M Condition Ba
sed Maintena Preventive
Location asters Shut Down
nce Maintenance
Maintenance
Integration
Maintenance with
Analytics
Equipment master Data Maintenance

Integration with Fixed Assets
Classification
Maintenance
Integration
Maintenance with
Analytics
Concept of Measuring Points

Possible sources of Measurement Data
Frequency of the measurement
Trigger of Maintenance activities based on the measurement data
Maintenance
Integration
Maintenance with
Analytics
Task Lists
Monitoring of Notification / Maintenance orders
Maintenance Execution
Maintenance
Integration
Maintenance with
Analytics
Shutdown Planning
Multiple Maintenance orders
Maintenance Execution
External services procurement
Maintenance
Integration
Maintenance with
Analytics
Attaching Maintenance orders to Projects

Scheduling of all orders thru Projects
 Tracking of Shut down using PM / PS
Maintenance
Integration
Maintenance with
Analytics
Maintenance
Integration
Maintenance with
Analytics
 Completion of maintenance
 Closing of Notification
Maintenance
Integration
Maintenance with
Analytics
Settlement of Orders – Cost Centre and other Cost Objects

Integration with other modules
 Finance/costing
• Asset accounting
• Cost center accounting
 Material Management
• Purchase requisition/Purchase order
• Service master
• Service entry sheet / Invoice
verification
Info. System
Integration with other modules
•Project system
• Budget
• Project order
• Shutdown planning
•Quality Management
• Calibration order
• Inspection recording
Info. System
Thank You for your time...

PM Overview New

Uploaded by

Copyright:

Available Formats

You might also like

PM Overview New

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PM Overview New

Uploaded by

Copyright:

Available Formats

Brief History of SAP

• 1972 Company started

• 1972 Company started

• TIGHTLY INTEGRATED SAP R/3 Application

• HIGHLY FLEXIBLE SAP R/3 Basis and

SAP R/3 is an integrated system designed to

The Presentation Layer

The Application Layer

The Database Layer

Presentation Layer Application Layer Database Layer

reside in: reside in: reside in:

Presentation servers: Application servers: Database servers:

General organizational units

Client e.g. company

Plant e.g. production sites

Storage location e.g. spares storage

Location-related organizational units

Maintenance plant e.g. plant with technical system

Location e.g. area, buildings

Company area e.g. production area,

Planning-related organization untis

Planning plant e.g. plant for maint. planning

PM planner groups e.g. foreman, work preparation

PM work centers e.g. mechanics, electricians

Functional locations are the physical locations

C1-M01 C1-M02 C1-B01 C1-B02

C1-B02-1A C1-B02-1B C1-B02-2A C1-B02-2B C1-B02-2C

C1-B02-2A/1 C1-B02-2A/2 C1-B02-2C/1 C1-B02-2C/2

Level 1 Motor Shaft/ Gearbox Level 1

Measuring Point & Counter

To standardize work flows

To plan maintenance orders more

To create maintenance plans more

Sequence of individual maintenance activities

Work steps (operation)

Maintenance work centers

Regular maintenance (servicing and inspection)

E Equipment task list

A General task list

Motors: general overhead

Operation, time, work center,

Quantity, BOM item,

Control key: PM01 .... Contents: vendor

Contents: work center purchasing group

Op. Sub-op. WrkCtr Description

0010 ME Clean engine

0020 ME Clean fuel pump

0040 ME Change oil

0050 ME Check oil level

high availability of • Customer requirements

technical systems, for • Reduction of system malfunctions

example, production • Reduction of system restart costs

plants, in the long • Extension of system life

• Better capacity load control

• Reduction of repair costs

Time-Based Performance-Based Condition-Based

Package 4 Pressure check

Maintenance plan data Operations