Upload
gaurav-arora
View
143
Download
32
Tags:
Embed Size (px)
DESCRIPTION
Overview
Citation preview
SAP
Plant Maintenance Module
Overview Presented by Sourabh Sharma
Copyright 2004 Accenture All Rights Reserved.
Accenture, its logo, and High Performance Delivered are trademarks of Accenture.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 2
2 | 21 Oct, 2004 | oSAP Program
Agenda
1. Introduction about PM
2. Structure of Organization with a view to PM
Functional Location
Equipment
BOMs
3. Type of maintenance
Corrective maintenance
Master data in corrective maintenance
Corrective maintenance process
Preventive maintenance
Master data in preventive maintenance
Preventive maintenance process
Refurbishment
Refurbishment process
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 3
Introduction to Plant Maintenance
What?
Planning, processing and documenting of repair tasks for
corporate operation and production resources.
Why?
To maintain the various resources of plants in order to ensure the
smooth and efficient working.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 4
Activities under Plant Maintenance :
Inspection
All measures which establish the actual condition of a technical system
Preventive maintenance
All measures which maintain the ideal condition of a technical system
Repair / Breakdown Maintenance
All measures which restore the ideal condition of a technical system
Maintenance Projects
All Measures required to make modifications or add to existing technical system
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 5
Planning Organization Structuring
Centralized Maintenance Planning
The company has several maintenance plants, however, only one plant in which maintenance planning is performed.
Decentralized Maintenance Planning
The company comprises several maintenance plants. Each plant performs its own maintenance planning.
Partially Centralized Maintenance Planning
The company comprises several maintenance plants. Some of the maintenance plants perform their own maintenance planning, others do
centrally.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 6
Structuring
Maintenance Plant
The maintenance plant for a technical object is the plant at which it is installed
E.g. Clarification plant C1 is located in plant 0001. Plant 0001 is therefore the maintenance plant for the clarification plant C1.
Maintenance Planning Plant
The maintenance planning plant for a technical object is the plant in which the maintenance tasks for the object are planned and prepared .
E.g. The maintenance plant for the clarification plant C1 is plant 0001. Plant 0001 does not perform its own maintenance planning. It is
assigned to plant 0002 . The maintenance planning plant for the
clarification plant C1 is therefore plant 0002.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 7
7 | 21 Oct, 2004 | oSAP Program
Master data objects
Plant specific master data objects:
Work center
Functional location
Equipment
Assembly
Bill of material
Document and links
Object network
Global master data objects:
Material master
Classification classes and characteristics
Catalogues
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 8
8 | 21 Oct, 2004 | oSAP Program
Technical Objects
= Functional location
= Equipment
= Bill of materials
= Material
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 9
9 | 21 Oct, 2004 | oSAP Program
Functional location
Is a multi-level hierarchical breakdown structure
of machinery. Individual equipments can be
installed within this hierarchy.
Provides a context for executing and recording
maintenance tasks.
Provides a framework to monitor and track costs.
Provides a framework to monitor and track
location of equipments.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 10
10 | 21 Oct, 2004 | oSAP Program
Equipment
Equipment is a uniquely identifiable physical machine, upon which work can be carried out and
about which costs and history can be recorded.
More than one piece of equipment can be installed at a functional location.
Equipment should be created if:
Individual data is to be managed for the object (for example, year of construction, warranty period, usage sites).
A record of the maintenance tasks performed for the object must be kept (e.g. for insurance or legal inspection purposes).
Technical data on the object is to be collected and evaluated over a long period of time.
The costs of maintenance tasks are to be monitored for the object. Records of usage times at functional locations are required for the object. Documents and BOM follow an equipment irrespective of installation location.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 11
11 | 21 Oct, 2004 | oSAP Program
Movements of an equipment
Functional Location Functional Location
Functional Location
Equipment Equipment Equipment
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 12
12 | 21 Oct, 2004 | oSAP Program
Equipment vs. functional location
Technical object Functional location Equipment
This is relatively stable,
may not be changed in
years
This is laid into a certain
position and it can be
changed more often
Example Turbine Motor
Oil pump
Shaft
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 13
13 | 21 Oct, 2004 | oSAP Program
Equipment design
If the object at a functional location will never move physically, such as a storage tank, it is not necessary to set up an equipment record. Any work can be raised against the related functional location.
Determine movable and non-movable machines to see whether an equipment needs to be created or not.
Equipment can be installed on or dismantled from either a superior equipment or a functional location.
Equipment needs to be installed on the correct functional location during conversion.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 14
14 | 21 Oct, 2004 | oSAP Program
Bill of material
A maintenance Bill Of Material (BOM) is a structured list of the components (i.e. functional location or equipment) or an assembly (material).
The BOM contains object numbers of individual components together with their quantity and unit of measure. The components can be Stock or Non-Stock Spares or Assemblies, which in turn can be described using maintenance BOMs.
Specifies only maintenance relevant components.
Maintenance BOMs are primarily used for the following purposes:
Structure description
A maintenance BOM describes the structure of a technical object or material. Using maintenance BOM you can specify exactly where maintenance tasks are to be performed on a Technical Object.
Assignment of spare parts
A maintenance BOM is used in PM to assign spares for a technical object for documenting and choosing materials.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 15
15 | 21 Oct, 2004 | oSAP Program
Bill of material structure
Text Data Quantity Data Administrative Data General Data
BOM Header
Sub-Item
Item Category Item Status Purchasing Data
BOM Item
Functional
Location
Equipment
Material Material
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 16
16 | 21 Oct, 2004 | oSAP Program
Bill of material design
Use of generic BOMs (i.e. Material BOMs) rather then specific
functional location or equipment BOMs.
Material BOM - A generic BOM is applicable to one or many
equipments or functional locations. By using generic material
BOMs, maintenance is simpler since there are less BOMs.
Spare Parts will be in SAP as part of the BOM.
Material need to be defined before the BOM can be built.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 17
17 | 21 Oct, 2004 | oSAP Program
Document and links
Offers document references and an easy access to related
documents for
functional locations,
equipments and
machine models (materials).
Access within master data, notifications and work orders.
Requires organized servers and folder structures
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 18
18 | 21 Oct, 2004 | oSAP Program
Material master
Maintenance relevant materials are for example:
spare parts
assemblies
common machines
All data of a material is integrated in one master record.
Integration also enables the master data to be used jointly by
purchasing and other areas like inventory management and
invoice verification.
In maintenance processing materials are used e.g. in ordering and
reserving spare parts.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 19
19 | 21 Oct, 2004 | oSAP Program
Classification classes and characteristics
Characteristics An attribute
describing an object
1. Create
characteristics
Class A group of objects
that has the same or
similar properties
2. Create a class
Object A classifiable unit 3. Link the class to an
object
Characteristics
value
Acceptable values of
a characteristic
4. Assign values for
characteristics
Pump capacity,
Pressure
Pumps, Electric
motors
Equipment,
Functional location
Pump capacity: 2000
l/s, Pressure: 1,6
MPa
Description Example Method
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 20
20 | 21 Oct, 2004 | oSAP Program
Catalogues
Maintenance catalogues are groups of standardized codes used to report
technical history for work that has been performed.
There are various types of catalogues that can be defined in SAP. Typical
ones are:
Object part catalogue allow the user to specify the specific part of a piece of
equipment or functional location that work is being requested or performed
for.
Fault code catalogue allow the user to specify the type of damage that has been
observed.
Cause code catalogue allow the user to specify the root cause.
Activity code catalogue allow the user to specify what activities were carried out
to fulfill a work request or to document work that was carried out.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 21
21 | 21 Oct, 2004 | oSAP Program
Catalogues
Technical history associated with the repair and maintenance of
specified equipment provides a basis for monitoring plant and
equipment integrity, such as:
Frequency of failure
Failure grouping and analysis
Impacts of maintenance strategies (planned Maintenance, corrective
maintenance, run to failure)
Component reliability analysis
Support to report analysis
Standardized codes enable benchmarking.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 22
22 | 21 Oct, 2004 | oSAP Program
Catalogue structure
Object part Task
Malfunction Action
Object part Task
Malfunction Action
Object Part Causes Task
Damage Activities
Code Code Code
Code-
group
Code-
group
Code- group
Catalogues for:
Catalogue Structure: Example :
Catalogue
Code Group
Code
Malfunction Catalogue
Mechanical Malfunction
Code
010 Corrosion 020 Broken Glass 030 Defect Engine . . . . . .
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 23
Corrective Maintenance process
Corrective Maintenance
process
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 24
24 | 21 Oct, 2004 | oSAP Program
Corrective maintenance process
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 25
25 | 21 Oct, 2004 | oSAP Program
Description of the process
The corrective maintenance planning process
Starts with creation of notification,
either a fault report
or a maintenance request,
ends with the creation of a maintenance work order,
includes several decision points whether to
create maintenance work order,
postpone to later or
cancel request.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 26
26 | 21 Oct, 2004 | oSAP Program
Notification life cycle
Notification
creation
Notification
review
Postpone/
cancel/
continue
Put in process Assign to
order
Notification
is created to
report a fault
or request
for
maintenance
Notification
in the
system can
be reviewed
and
updated
When
notifications
are
reviewed, a
decision is
made
whether to
continue
with the
notification
immediately,
to postpone
it until later
or to cancel
it
When
decision
has been
made to
continue
with the
notification,
it will be put
in process.
Once the
notification
is put in
process it
can be
assign to a
work order
Complete
notification
After the
completion
of the
notification,
it is no
longer
possible to
change /
update it.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 27
Standard Maintenance Cycle Data objects
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 28
Maintenance Order
What is a Maintenance Order ?
It is a detailed planning of the maintenance task which has to be
performed.
Why Maintenance Order ?
Plan tasks in detail with regard to type, scope, dates and resources.
Monitor the execution of tasks.
Define rules for account assignment, settlement and budgets.
Enter, assign and settle the costs which arise from tasks.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 29
Information from the Maint. Order
Location or Equipment needing the repair ( inherited from the Notification data).
List of activities to be performed and estimated completion times.
Maintenance resource(s) to perform the activities.
Spares required for the repair.
Cost of the repair jobs carried Planned & Actual.
Where the costs of the order would be settled.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 30
Maintenance Order Structure
Elements of Maintenance Order
Order header For example: Order Type, Dates,Plant, Main object,
Priority, Description, Maintenance Activity type
Object list For example:- Functional Locations, Equipment
Maintenance Notifications, Assemblies.
Operation For example: Work Centre, Control key, Descriptions
Standard time, Activity type,
Material list For example: Material, Quantity, Storage Location
Production resources/tools
Settlement Rule
Costs
(Estimated / Planned / Actual)
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 31
Maintenance Order in SAP
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 32
32 | 21 Oct, 2004 | oSAP Program
Notification vs. PM work order
Notification
Technical object
Classes
damage
cause
Activity history
No costs
Work order
Object list
Operations
work center
material
quantity
resources
Settlement rules
Costs
estimated
planned
actual
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 33
33 | 21 Oct, 2004 | oSAP Program
Description of the process
Work order planning and scheduling
Starts after the maintenance work order has been created and finishes
when the work order is scheduled to execution.
The process includes planning of material
stock material from the warehouse
non-stocked material to be purchased for the order
and planning of resources
own resources
external services to be purchased.
The scheduling part co-ordinates timing of work orders.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 34
34 | 21 Oct, 2004 | oSAP Program
PM work order system status
System status
Automatically created
Shows actions taken or not taken
The work order can have several system statuses
Ex:
CRTD, order created
MANC, material availability not checked
PRC, precosted
PRT, work order printed
REL, work order released
PCNF, work order partially confirmed
TECO, work order technically completed.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 35
35 | 21 Oct, 2004 | oSAP Program
External services
External services will be processed in two different ways:
Frequently used contractor with a long time contract
Processed using an internal work order with an external work center.
Sporadically used contractor
Processed using purchase requisition and material master.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 36
36 | 21 Oct, 2004 | oSAP Program
Stock material process flow
Component
assignment
Material
reservation
Order
release
Printing
Goods issue
Automatic
availability
check
Availability
check
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 37
37 | 21 Oct, 2004 | oSAP Program
Non-stock material process flow
Component
assignment
Purchase
application
Purchase
order
Goods receipt
Invoice receipt
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 38
38 | 21 Oct, 2004 | oSAP Program
PM work order release
Effects of order release:
Reservation effective, can be
withdrawn
Papers can be printed
Confirmation possible
Goods movement possible
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 39
39 | 21 Oct, 2004 | oSAP Program
Description of the process
Work order execution
Starts when the work order has been released for execution,
ends when the work has been completed and the costs are settled,
includes
material issue,
execution of the work,
time reporting,
updating notification,
updating technical object and
cost settlement.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 40
40 | 21 Oct, 2004 | oSAP Program
Technical order confirmation
Before the work order can be completed:
Time must be
confirmed
Goods movement
reported
Activity reports
completed
0013456998 Measurement
readings recorded
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 41
41 | 21 Oct, 2004 | oSAP Program
Technical completion
Effects of technical completion:
Limited ability to change order
Create settlement rule
Deletion flag for purchase requisitions
Close open reservations
Close open capacities
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 42
42 | 21 Oct, 2004 | oSAP Program
Reverse Technical completion
Effects of reverse technical completion:
Order becomes modifiable again
Status REL is set
Locations and account assignment
data are recopied from the object
Open purchase requisitions are
recompiled
Open reservations are recompiled
Open capacities are recompiled
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 43
43 | 21 Oct, 2004 | oSAP Program
Order cost
Estimated costs
are entered at
order creation
Planned cost are
calculated at order
planning
Actual costs are
calculated at material
issue and time
confirmation
All costs can be viewed on work order
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 44
Preventive Maintenance Preventive Maintenance
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 45
Master Data in Preventive
Maintenance
Master Data in Preventive
Maintenance
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 46
46 | 21 Oct, 2004 | oSAP Program
Master data objects
Plant specific master data objects:
Task list
Maintenance item
Measuring point
Global master data objects:
Maintenance strategy
Maintenance plan
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 47
47 | 21 Oct, 2004 | oSAP Program
What is a task list
Describes a sequence of individual operations which have to be completed
Related to a functional location and equipment
Types of task list
General task lists are maintenance tasks lists - sequence of tasks defined and managed
centrally and used for scheduling work on multiple equipments/sites
Object specific task lists are specific to functional locations or equipment
STEPS
EQUIPMENT
LABOUR
MATERIALS
TASK LIST
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 48
48 | 21 Oct, 2004 | oSAP Program
e.g. strategies, maintenance planner
group, work center, equipment
e.g. strategy, Task List planner
group, main work center Task list
header
Task list Task list
header header
e.g. Frequency
e.g. work center, description, time
control key, external processing data,
maintenance packages
e.g. work center, description, timing,
control key e.g. external service Operation Operation Operation
Maintenance
package
Maintenance Maintenance
package package
e.g. operation, time, work center,
description, control key Sub-operation Sub-operation Sub-operation
e.g. quantities, BOM items,
item category, unit of measure
e.g. Material Numbers quantities, BOM items,
unit of measure
e.g. amount, type e.g. Mobile Crane
Material Material Material
Production
resources/tools
Production Production
resources/tools resources/tools
Maintenance task list structure
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 49
49 | 21 Oct, 2004 | oSAP Program
Preventive maintenance strategy
A maintenance strategy is a set of defined frequencies or packages
with scheduling parameters assigned to them
Time based maintenance strategy samples:
Weekly
Monthly
3 Monthly
Yearly
Counter based maintenance strategy samples:
Hours run
Liquid pumped out
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 50
50 | 21 Oct, 2004 | oSAP Program
Preventive maintenance plan
PLAN:
Started on date Some parametres Frequency set 1m 3m 6m 1a 3a
"Maintenance strategy" A
ITEM 1
WO Header info Tasklist: A
check x
calibrate x
tune x
replace valve x
ITEM 2
WO Header info Tasklist
lubricate x
balance x
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 51
51 | 21 Oct, 2004 | oSAP Program
Measuring point
Are used to enter measurements and counter readings (quantitative operating data) for technical objects.
Measuring point is a physical and/or conceptual location at which a condition is described.
Accumulated totals can trigger a PM Notification or PM Order.
Typical situations of use are:
Counter-based maintenance (preventive maintenance every 1000 production hours).
Condition-based maintenance (preventive maintenance when brake pad minimum thickness has been reached).
Condition of the object is needed to be documented at a particular point of time (e.g. legal, health and safety reasons).
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 52
52 | 21 Oct, 2004 | oSAP Program
Measuring point
Measurements and counter readings are represented in SAP as
measurement documents.
Measurement and counter reading data can be entered into SAP
e.g.:
Manually using SAP user interface.
Manually using browser and transferring it to SAP via Internet.
Semi-automatically using barcode reader and transferring it from
external system to SAP via interface.
Automatically transferring it from external system to SAP via interface.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 53
Preventive Maintenance process Preventive Maintenance Process
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 54
54 | 21 Oct, 2004 | oSAP Program
Description of the process
Normal PM preventive maintenance process
Starts with the creation of a maintenance strategy.
Ends with automatic generation of work orders.
Includes maintenance task lists, plan creation and maintenance plan
scheduling.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 55
55 | 21 Oct, 2004 | oSAP Program
Preventive maintenance planning framework
1M * 1000 H
2M * 8000 H
3M * 10000 H
etc.
Service Master
Strategy
Maintenance Plan
Package
Material Master Vendor /Contract
Operation
Call Object /Work Order
Standard Text
Sub Operation
Object List Maintenance Item
Task List
Counter *
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 56
Refurbishment process Refurbishment Process
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 57
57 | 21 Oct, 2004 | oSAP Program
Description of the process
Refurbishment
The refurbishment process starts with creation of a refurbishment work
order for a material number and
ends with completion of the work order.
Planning and scheduling of the refurbishment work order follows the
normal planning and scheduling process flow.
After the refurbishment work has been executed the refurbished
material may be put to stock.
For refurbished equipment the status is changed.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 58
58 | 21 Oct, 2004 | oSAP Program
Additional details
Refurbishment cases can be handled in different ways:
Equipment with normal PM work order, where equipment does not
have SAP serial number. These are major machines.
Smaller machines and major components with refurbishment work
order. These have normal material number with split valuation and
possibly a serial number.
Smaller low value components with standing work order and zero stock
value.
Before the equipment is refurbished, its status will be changed to
waiting to be refurbished.
2004 Accenture All Rights Reserved. Copyright 2010 Accenture All Rights Reserved. 59
59 | 21 Oct, 2004 | oSAP Program
Questions?
Any Questions?
Thank you