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Plant Maintenance
The goal of this session is to give you an introduction to
and a basic understanding of:
SAP PM philosophy
SAP PM terminology
SAP PM screens
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SAP R/3 Plant Maintenance
Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis
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Background Philosophy
Business can not afford to have plant idle
Business can not afford to have plant running inefficiently
Business demands a consistently high quality of product
from plant
Legal, Safety and Environmental issues demand a clean
efficient plant
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SAP Plant Maintenance
Solutions for management and maintenance of technical
systems
Maintenance incorporates:
Inspection: determine the actual condition
Maintenance: maintain the ideal condition
Repair: restore the ideal condition
Construction and modification
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Scope of PM Activities
Management of operational systems and technical
resources
Regular activities scheduled via Maintenance plans
Malfunctions entered as notifications & passed to planning
Maintenance Orders for work required
type of activity, task steps, & resources
Completed Orders = task related, function and object
oriented history
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Functionality
Can fulfil all day-to-day processing requirements of Plant
Maintenance
Experience and suggestions of varied customers used in
development
Fully integrated with other modules
Materials Management
Purchasing
Inventory Management
Financial Accounting
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Functional Overview
Plant Maintenance (PM)
- Technical Objects
- Work centers
- Main. task lists
- Maintenance planning
- PM Processing
- Capacity planning
- Information system
SD
CO
MM
R/3
PP
AM
Client / Server
PS
ABAP/4
QA
OC
PM
HR
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FI
IS
Different (Major) Maintenance
Types
System generated Work Orders
Time dependent
Manual Intervention
Notifications or
Directly created Work Orders
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SAP R/3 Plant Maintenance
Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis
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Plant Maintenance, a lot of terms
PM Order
Work Center
Maintenance Plan
Maintenance Strategy
Maintenance Item
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Structuring
Reduces recording and management effort
Simplifies processing
Enables better planning and evaluation
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Structuring
Functional: location or process oriented using hierarchies
Object related: description of every piece of equipment
Technical: allocate objects to different classes
Accounting: allocate objects to cost centres or assets
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Functional Location
Definition:
an element in a technical structure,
representing an area of a system where an
object can be installed / maintained
Functional
Location
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Reasons for:
Need to represent system
according to function
PM tasks are planned / executed for
individual areas
Records are kept per individual area
Costs are followed per individual
area
Functional Location Structure
San Jose
Production
Test
...
Process
LINE 1
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LINE 2
LINE 3
Functional Location Structure
Structure Indicator: ABC1
Edit Mask:
XXXX-XXX-XX-XXX-XXX-XXX
Hier. Levels:
1
2 3
4
5
6
FUNCTIONAL LOCATION
DESCRIPTION
PL01
San Jose
PL01-PRD
PL01-PRD-PR
PL01-PRD-PR-LN1
PL01-PRD-PR-LN2
PL01-PRD-PR-LN3
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Production
Process
Line 1
Line 2
Line 3
Functional Location
Structure Indicator
To describe the number structure of Functional Locations
To define the hierarchy levels
To describe all similar functional locations in the same way
A strict top down definition
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Create Functional Location
Structure Indicator
Menu Path:
Tools - Customizing - Configuration - Logistics - Plant
Maintenance - Master Data - Technical Objects - Functional
Location - StructIndicator
1. Display:
PL01
2. Create:
Structure Indicator, ABCX (AAA-XXXX-XX)
3. Exercise (1):
See Participant hand out (Struct. Indicator)
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Functional Location Structure
San Jose
PL01
PL01-PRD
Production
Test
LINE 1
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PL01-PRD-PR
Process
...
San Jose
LINE 2
LINE 3
PL01-PRD-PR-LN1
PL01-PRD-PR-LN2
PL01-PRD-PR-LN3
Production
Process
Line 1
Line 2
Line 3
Create Functional Location
Menu path:
Logistics - Plant Maintenance - Technical Objects Functional Location
1. Display:
Functional Location PL01
2. Create:
Functional Location, usage of TRW (2 levels)
3. Exercise (2):Functional Location
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Equipment
Equipment
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Definition:
An individual, physical object
which is to be maintained
independently
Equipment data
General data
Location data
PM data
Sales and distribution data
Multi lingual texts
Link to documents ( drawings, ref. manuals etc)
Link to functional location
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Create Equipment
Menu Path:
Logistics - Plant Maintenance - Technical Objects Equipment
1. Display:
Equipment PT316
2. Create:
Equipment TD100
3. Exercise (3):
Equipment
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Object Link
Definition
a relationship between 2 technical systems (functional
location or equipment) horizontally
Use
To be able to analyse the impact on other systems when
another has malfunctions / planned maintenance
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Object Link, characteristics
Different types:
Pump A
Pump B
One-Way Link
Host A
Host B
Two-Way Link
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Object Link
Menu path:
Logistics - Plant Maintenance - Technical Objects Equipment OR Functional Location - Object Link
1. Display:
Object Links #: 10000001
2. Create:
Object Links: PT316 and 15-PU-15A
3. Exercise (4):
Object Links
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Material Master views
Purchasing
Engineering
Accounting
Forecasting
Material
Master
record
Inventory
MRP
Sales
The Material Master Record is a central data object in the SAP system.
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Equipment Bill of Material
Definition:
a complete formally structured list representing all parts, material, documents
required to maintain an equipment
Equipment
Equipment
15-PU-15A
Spares
Spare
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Spare
Spare
Equipment Bill of Materials
Equipment
level 0
Equipment
Assembly
Assembly
Spare
Assembly
level 1
Spares
Spare
Spare
level 2
Assembly
Spare
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Spare
Spare
Equipment Bill of Materials
15-PU-15 A
5014-0042
5014-0043
5021-0031
7501-0459
7501-0532
1700-0014
1700-0015
1700-0023
1700-0028
etc.
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LUBRICATION PUMP
BEARINGS RHP.NH314
BEARINGS SKF.Q1314MA
BEARINGS RHP.N221 ECP
SEALS OIL 90 x 130 x 12
SEALS OIL 110 x 130 x 12
PUMP SHAFT 304L
PUMP IMPELLOR 304L
RINGS WEAR CASING POS NO 9-9/1
GASKET SETS
Create Equipment Bill of Materials
Menu path:
Logistics - Plant Maintenance - Technical Objects - BOM Equipment BOM
1. Display:
Equip. BOM PT316 or 15-PU-15Al
2. Create:
Equip. BOM TD100
3. Exercise (5):
Equipment Bill 0f Materials
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Elements in System Structuring
Functional
Location
Installation of one or more pieces of equipment at a
functional location
Equipment
Installed equipment
Assembly
Spares
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Equipment Bill of Materials
Assembly (material)
Bill of Materials
Install Equipment
Menu path:
Logistics - Plant Maintenance - Technical Objects Functional Location
1. Display:
Install Equipment PT316 (SLK-CR300-A1)
2. Create:
Install Equipment TD100 on BRU-level
3. Exercise (6):
Install Equipment
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Work Centers
A work center defines where an operation can be executed
(a machine or a group of machines ), or who is to carry out
an operation ( a person or a group of people).
In the work center you can calculate costs, capacities and
dates for the operations.
Work centers can be structured hierarchically. In this way
required and available capacity can be cumulated
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Work center, characteristics
Work center
Default
values
Task List
Costing
data
Scheduling
data and
available
capacity
Costing
Lead time
Scheduling
Capacity planning
2724,00
1200,00
124,00
4048,00
100
80
60
40
20
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Create Work Center
Menu path:
Logistics - Plant Maintenance - Work Centers - Work Center
1. Display:
Work Center, PMWC100
2. Create:
Work Center, PMWC500
3. Exercise (7):
Work Center
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Material
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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SAP R/3 Plant Maintenance
Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Task List
What work has to be done ?
Who is to do the work ?
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Task List
Work to be done
Resource
Disconnect Motor
Make a scaffold
Remove insulation
Replace A with B
Replace insulation
Connect Motor
Test
Electrical Department
External contract
External contract
Mechanical Workshop
External contract
Electrical Department
NA Mechanical Dept.
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Maintenance Task List
Definition:
a sequence of individual maintenance activities which must
be performed in order to fulfill a certain maintenance
requirement
Characteristics:
can be defined for a particular equipment or as a general list
multiple alternatives per task list
sequence of operations per task list
only one capacity requirement per operation
required material per operation
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Maintenance Task List
Material Allocation
Task List
operation 1
operation 2
operation 3
1 x Item A
2 x Item B
1 x Item C
Equipment
Equipment
Bill of Materials
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operation 4
Create Maintenance
Task List
Menu path:
Logistics - Plant Maintenance - Maintenance Task Lists Maintenance Task Lists - Equipment task lists
1. Display:
Maintenance Task Lists, PT316
2. Create:
Maintenance Task Lists, TD100
3. Exercise (8):
Maintenance Task Lists
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Maintenance Strategy
15
When are jobs to be performed ?
Yearly ?
Monthly ?
Weekly ?
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Maintenance Strategy
Definition:
a schedule of planned maintenance activities which should
take place at predefined intervals
Characteristics:
Independent of any equipment or functional location
schedule by either calendar or key-date
rules for early and late confirmation
variable number of maintenance packages
package has description, frequency and priority
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Maintenance Strategy
Example
Maintenance of pressurized
container
Package 1:
weekly routine check
Package 2:
monthly pressure check
Package 3:
yearly overhaul
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Display Maintenance Strategy
Menu path:
Logistics - Plant Maintenance - Maintenance planning Maintenance strategy
1. Display:
Maintenance Strategies, ST001
2. Exercise (9):
Maintenance Strategies
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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How to combine
Functional location
Equipment
Maintenance task list
What work has to be done ?
Who is to do the work ?
Maintenance strategy
When are jobs to be performed ?
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Usage of a Maintenance item
A maintenance item describes the activities to be carried
out on an object and their frequency
Note:
A Maintenance item IS NOT an Equipment (e.g. installation)
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Maintenance Item
Maintenance Item
Object List
Strategy
Primary Object
Location/account
assignment
Equipment #
Funct. locations
Task List
Operations
Description
The maintenance item describes the type of maintenance or inspection
activity to be carried out on a object (using short and long texts).
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Maintenance item
Due Dates
Activities
Maintenance strategy
Maintenance package
Task list
with operations
Maintenance Item
Maintenance objects with
tasks to be carried out
Maintenance Plan
Dates
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Create Maintenance item
Menupath:
Logistics - Plant Maintenance - Maintenance planning Maintenance Items
1. Display:
Maintenance Items, SLK-MP-03
2. Create:
Maintenance Items, TD100 (MI-SLK-TD01)
3. Exercise (10): Maintenance Items
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Maintenance Plan
Due Dates
Activities
Maintenance strategy
Maintenance package
Task list
with operations
Combination of
Maintenance
Strategies and
Task Lists
Maintenance Item
Maintenance objects with
tasks to be carried out
Maintenance Plan
Dates
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System generates
Work Orders based
on planned dates
Maintenance Plan
Describes dates and scope of the maintenance activities to
be performed
Characteristics:
combination of maintenance items
all items selected must have the same strategy
includes the cycle start date
basis for scheduling maintenance orders
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Maintenance Plan
Scheduling
The following data is used to automatically schedule
maintenance orders:
The start date and last completion confirmation from
the plan
opening period (% of cycle time)
shift factors (early / late confirmation) (Slide)
tolerances (based on smallest interval)
call interval (actual length of scheduling period)
the cycles and the task list from the item
the packages from the strategy
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Maintenance plan,
shift factors example
Planned
date
Confirmed
on
Next date
planned
Shift
factor
01.08.99
16.08.99
01.09.99
16.09.99
08.09.99
0%
100%
50%
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Maintenance plan, call status
Other possible
stati are:
When a maintenance
plan is scheduled all
orders get the status ON
HOLD
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Elements in Maintenance Planning
Maintenance Strategy
Maintenance
Strategy
Maintenance
packages:
time-dependent
activity-based
Maintenance Plan
Maintenance Call
Maintenance
Schedule
Schedule
forecast
Maintenance
Orders
Maintenance
Item
Objects
Funct. locations
Equipments
Task lists
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Create Maintenance plan
Menu path:
Logistics - Plant Maintenance - Maintenance planning Maintenance Plans
1. Display:
Maintenance Plans, MP-SLK-DEMO
2. Create:
Maintenance Plans, use MI-SLK-TD01
3. Exercise (11): Maintenance Plans
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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SAP R/3 Plant Maintenance
Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis
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Maintenance Order
PM planning
PM Notifications
PM Orders
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Direct order
creation
Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Notifications
Definition:
A document which holds all data which is needed to trigger an unplanned
maintenance activity or data on an activity performed already
Result from unplanned, reported
exceptions
Allow for planning of resources
Not used in critical situations, when
Order is entered directly
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Notification Types
Malfunction report:
Describes a malfunction, which normally affects the availability of
and object and leads to a maintenance order.
Activity report:
Describes a maintenance activity which has already been carried
out, not necessarily due to malfunction. For documentation
purposes.
Maintenance request:
A request for the maintenance department to carry out an activity
not based on malfunction.
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Notification Structure
NOTIFICATION HEADER
Date/Time/Reported by
Description
PM Object: Functional
location
Equipment
Assembly
NOTIFICATION TASKS
Dates
Task Description
NOTIFICATION ITEMS
ACTIVITIES
Damage location
Damage
Cause of Damage
Activity
Execution factors
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Create Notification
Menu path:
Logistics - Plant Maintenance - PM Processing - Notifications
Maintenance Notifications, 10000040, PT316
1. Display:
Maintenance Notifications, TD100
2. Create:
3. Exercise (12): Maintenance Notifications
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Maintenance Order
Definition:
PM Orders
A document used to:
plan the execution,
monitor the progress of maintenance activities in
detail
to collect all costs accrued during execution.
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Maintenance Order Creation
Based on one or more existing notifications
Created automatically based on a maintenance plan
Entered manually
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Functional Procedures
PM Organization
Plants
Direct order
creation
PM planning
PM Requirements/
notifications
Planners
PM Orders
Workshops
Capacities
Material
Internal services
External services
PM Objects
Functional
Location
Completion confirmations
Equipment
Assembly
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PM History
Downtimes, problems
Costs, Measures
PM Order Structure
HEADER
number, description, date, type, priority
LOCATION and
ACCOUNTING
OBJECT
physical location, suggested account assignment
functional locations, equipment, assemblies, notifications
SETTLEMENT
planned/actual costs, final account assignment
OPERATION
description of work to be done, scheduling data
COMPONENT
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materials needed for work
PM Order Integration
Order Costs maintained throughout the cycle (Finance)
Reservations for planned materials (MM - inventory)
Requisitions for non-stock items or services (MM purchasing)
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Order Costing
PM ORDER
Internal processing
Op. 10 ME 3 hrs
Op. 20 EL 1 hr
External processing
Op. 30 EXT 1 hr
Stock material
2 pcs material ABC
Non-Stock material
2 pcs material XYZ
COSTS
Internal
Processing
500
External
Processing
150
Stock
Material
300
Non-stock
Material
Total
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500
-------1450
Maintenance Processing
for Unplanned Tasks
Malfunction, error
request, activity
Requesting
a task
2
PM NOTIFICATION
What
When
Where
--------------------------Techncal
information
Breakdown
Create the order
Planning the task
Who
When, for how long
What steps
Resources
7
Completion
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Execution
material issue
procuring PRTs
worksteps
Releasing
the order
Technical information
Breakdown
Causes
Objects affected
Activities
PM History
Maintenance Processing
for Unplanned Tasks
1. Reporting a malfunction or a defect in a system or part thereof (ie
describing the condition of the system
2. requesting a maintenance task
3. creating a maintenance order and planning the task
4. releasing the maintenance order
5. executing the order
6. completing the task and confirming completion of order
7. entering technical information such as findings, cause, downtime,
activities
8. completing the order and the notification, storing relevant data for
evaluations, and for planning future maintenance activities
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Maintenance Order Status
CRTD : after creation
REL(R) : released (rejected) - papers can be printed, time recorded
and material issued
PRC : pre-costed (standard costs have been calculated)
(P)CNF : (partly) confirmed - time used has been recorded
MSPT : missing parts
TECO : technical completion
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Create Maintenance Order
Menu path:
Logistics - Plant Maintenance - PM Processing - Orders
Maintenance Orders, 900098
1. Display:
Maintenance Orders, with reference to 10000040
2. Create:
3. Exercise (13): Maintenance Orders
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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SAP R/3 Plant Maintenance
Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis
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Maintenance History
Usage
History
Master
records
Functional
Equipment
Location
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Order
History
PM Order
Costs
Materials
Operations
Notification
History
PM
Notification
View Maintenance History
and analysis
Menu path:
Logistics - Plant Maintenance - PM Processing - History - Notification List Display
Logistics - Plant Maintenance - PM information system - Standard
Analyses - Manufacturer - Display
Exercise (14):
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History and PM information system
Plant Maintenance Process
Summarized
You should be able to
Create a Functional location (structure)
Create and install an equipment
Create a maintenance plan
Create notifications
PM order handling
Exercise 15
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Plant Maintenance Process
