PM Master Data 2. Course Objective Understand the concepts of Bills Of Material (BOM) Work Center Task List Above tasks are divided in to three parts

PMPMMaster Data 2Master Data 2

Course ObjectiveCourse Objective

Understand the concepts of

Bills Of Material (BOM)Work Center

Task List

Above tasks are divided in to three parts from Part 1 to Part 3

Part 1 – BOM Course titlesPart 1 – BOM Course titles

Bill of Material

Equipment BOM

Functional Location BOM

Material BOM

BOM Course Objectives BOM Course Objectives

Describe the concepts and criteria for: Functional Location BOM Equipment BOM Material BOM

Understand BOM usage for the planning of maintenance activities

Bill of MaterialsBill of Materials

A Bill of Material (BOM) is a structured list of components that make up an object.

A BOM is used to represent the structure of an object during spare part planning.

Assignment of Bill of MaterialAssignment of Bill of Material

Two ways of assigning BOM to a technical object are:

Direct assignment or Indirect assignment

Direct assignment is done through the creation of an Equipment or Functional location BOM. The BOM is created specifically for that technical object.

Indirect assignment is done through the creation of a Material BOM that is entered into the Construction type field in the technical object record.

Part 1 – Course titlesPart 1 – Course titles

Bill of Material

Equipment BOM


Material BOM

Equipment BOMEquipment BOM

Direct assignment of the bill of materials to the equipment record.

List of components (stock and non-stock) that are regularly used during the maintenance of the equipment.

Will be created when: A new equipment record is created. An existing equipment record

requires a spare parts list.

Creating Equipment BOMCreating Equipment BOM

The BOM is created with reference to an individual piece of equipment.

Components are specific for the individual piece of equipment.

Enables material planning in maintenance orders and task lists to be performed more effectively.

Multiple BOM for an equipment can be created.

Maintaining Equipment BOMMaintaining Equipment BOM

Updating equipment BOM ensure data integrity

Equipment BOM are changed when: Additional component required Existing component needs to be removed

or substituted or quantities changed BOM header description needs to be

changed

Equipment BOM are deleted when: Equipment master record flagged for

deletion


Bill of Material

Equipment BOM


Material BOM

Functional Location BOMFunctional Location BOM

Direct assignment of the bill of materials to the functional location.

List of components (stock and non-stock) that are regularly used during the maintenance of the functional location.

A functional location BOM is used in the following situations: When identical equipments are installed. Where common spares used for more

than one equipment (Coupling used by motor and gearbox).

Creating Functional Location Creating Functional Location BOMBOM

The BOM is created with reference to an individual functional location.

Components are specific for the individual functional location or equipment installed at the location.


A functional location BOM can contain material BOM.

Maintaining Functional Location Maintaining Functional Location BOMBOM

Functional location BOM are changed when: New component required Existing component needs to be removed or

substituted or quantities changed

Functional location BOM are deleted when: Functional location master record flagged for

deletion Functional location BOM created incorrectly

Updating functional location BOM ensures that accurate information is available for planning


Bill of Material

Equipment BOM


Material BOM

Material BOMMaterial BOM

A material BOM is created with a direct link to a material master record.

Contains a list of stock or non-stock components

Can be used by multiple technical objects.

A material BOM is used in the following situations: For assemblies For identical equipment that have a

material number.

Material BOM cont..Material BOM cont..


A material BOM can contain other material BOM.

Can be created with reference to another material BOM.

Transaction code tipsTransaction code tips

IB01 – Create Equipment BOMIB02 – Change Equipment BOM

IE02 – Link Material BOM to Equipment

IB11 – Create Functional Location BOMIB12 – Change Functional Location BOM

MMP1 – Create PM Assembly

CS01 – Create Material BOMCS02 – Change Material BOM

Part 2 – Work center Course titlesPart 2 – Work center Course titles

Work center over view

Work center Maintenance

Work center hierarchy

Course Objectives Work Course Objectives Work CentersCenters

Discuss the concepts of work centers

Understand the different work center categories and its usage.

Discuss the concepts of a work center hierarchy

Create and manage work centers

Work CentersWork Centers

A labor work center is a grouping of craftsmen that perform maintenance work.

A work center can also represent a piece of equipment used in maintenance operations

The work center is used to plan maintenance activities in task lists and maintenance orders.

Work Centers DataWork Centers Data

Default values maintained in the work center data are copied to the PM order.

Costing information used to determine the activity cost.

Capacity details are used to schedule the operation.

Operation can be scheduled using scheduling information





Creating Maintenance Work Creating Maintenance Work CentersCenters

When creating a work center, the work center category must be specified.

Work center can be created by copying from existing work center.

The information from the existing work center is copied into the new work center and can be changed as required.

Work center can be renamed

Main Work CenterMain Work Center

A main work center will be used in the main work center field for the following objects:

Task lists Maintenance orders Maintenance notifications Equipment Functional locations

Used within capacity evaluation to aggregate operational work centers.

PM Machine Work CenterPM Machine Work Center

Represent fixed machines and fleet objects that need to be scheduled and costed in maintenance orders.

PM Machine work centers are used to assign against operations in maintenance task lists and orders.

Used within capacity evaluation.

Work Center CapacityWork Center Capacity

The capacity of a work center is the total number of hours per day a work center can perform maintenance activities.

Commonly used three work center capacity categories are: 001 Machines 002 Labor 022 Pooled capacity

For categories 001 & 002 the capacity is defined within the work center.

Pooled capacity is created outside the work center and assigned to the work center.

Pooled CapacityPooled Capacity

Allows you to assign multi-skilled technicians to more than one work center.

The capacity of the multi-skilled technicians is created as a pooled capacity separate to the work centers.

The pooled capacity is then allocated to all relevant work centers.

When maintenance activities are assigned to the work centers the pool capacity is used in capacity evaluation and leveling reports.

If a change is made to the pool capacity it is reflected in all relevant work centers’ available capacity.





Work Center HierarchyWork Center Hierarchy

Work centers are grouped together into a work center hierarchy.

Each level within the hierarchy will be represented by a work center(s). Can consists of 3 levels.

Hierarchies are used in capacity planning to cumulate available capacity and capacity requirements.

Can consist of 3 levels.

The lowest level of the hierarchy will consists of operational work centers.

The second lowest level of the hierarchy will consists of main work centers.

Hierarchy work centers are used in the first level of the hierarchy.


IR01 – Create Work Center

IR02 – Change Work Center

CR11 – Create Capacity

CR22 – Change Hierarchy

Part 3 – Task List Course titlesPart 3 – Task List Course titles

Task List over view

Equipment Task List

Functional Location Task List

General Task List

Course Objectives Task ListsCourse Objectives Task Lists

Describe the concepts and criteria for: General Task Lists Equipment Task Lists Functional location Task Lists

Understand usage of maintenance task lists for the planning of maintenance activities.

Understand usage of maintenance task lists are used within preventive maintenance.

Maintenance Task ListsMaintenance Task Lists

A maintenance task list is a pre-defined sequence of maintenance events that are performed repeatedly within a company.

Maintenance Task ListMaintenance Task List

Task lists are used for preventive and corrective maintenance

Task lists are copied into the Maintenance order

Maintenance Task List StructureMaintenance Task List Structure

Task List Header DescriptionGeneral data

Task List operationOperation sequenceStandard expected hours

Component / PRT assignmentRequired components can be assigned PRT can be assigned to an operation

Task List Header DetailTask List Header Detail

Task list are created for each plant.

Each task list will belong to a task list group and will have its own counter number.

Statuses are used to control the creation and use of the task lists.

A maintenance strategy is entered if the task list is created for use within a strategy controlled maintenance plan.

The profile is used when creating a task list to default details into the task list.

Task List Operation DetailTask List Operation Detail

The operations of the task list detail the activities to be performed within the task list.

A task list can contain multiple operations.

There are two types of operations: Internal Processing Operations External Processing Operations

Depending on the operation control key the operation is planned differently.

Internal Processing OperationsInternal Processing Operations

Following are the required details to create an internal processing operation: Work center Control key Operation description Work effort Number of people

An operation can only have one work center assigned.

Additional work centers can be added to add additional operations.

External Processing OperationExternal Processing Operation

To plan maintenance activities for external processing use:

Defined Control key indicating it as external operation. This control key will allow you to specify services using service master

records for work agreed between the vendor and SABIC. (e.g. motor overhaul, motor rewiring) or using text services

Purchasing information containing following info must be entered.

Planned delivery time Cost element Material group Vendor Purchasing Group Purchasing Organization

Service SpecificationService Specification

Against the external operation the individual services are planned.

Service master records or text services are used to plan the required activities.

For each service the quantity, unit of measure and price is required.

Task List Operation Detail Task List Operation Detail (Cont.) (Cont.)

It is possible to assign the following items for an operation:

Components Production Resource Tools Maintenance Packages Relationships Inspection Characteristics

Additional text to describe the operation can be entered using long text for an operation.

Production Resource & ToolsProduction Resource & Tools

If a PRT is required to complete an operation the PRT is planned against the operation.

The required usage and PRT control key are entered for each PRT assigned to the operation.

Maintenance PackagesMaintenance Packages

If the task list is used for a strategy based preventive maintenance plan, the strategy is entered on the task list header.

One or more maintenance packages are assigned to the individual operations.

The maintenance package defines when the operation is to be performed i.e the frequency.

When the maintenance package falls due, the operations assigned to the package will be included in the maintenance order.


Task List over view

Equipment Task List


General Task List

Equipment Task ListsEquipment Task Lists

Created specifically for a piece of equipment and is unique for that piece of equipment.

It is possible for an equipment to have more than one task list created.

Each task list is given a counter number to identify it.

Equipment task list can be created by copying and required data can be changed.


Task List over view

Equipment Task List


General Task List

Functional Location Task ListsFunctional Location Task Lists

Created specifically for a functional location and can only be used for that functional location.

It is possible to have more than one task list created for a functional location.

Each task list is given a counter number to identify it.

When creating a functional location task list is possible to copy from an existing task list and make the necessary changes.


Task List over view

Equipment Task List


General Task List

General Task ListsGeneral Task Lists

Used as a common task list for equipment or functional locations. Not specific to any equipment and functional location

Logical naming conventions are given to general task list group names. Can also be identified with group name and counter

Each task list within a general task list group has a unique counter.

Used for preventive, corrective and refurbishment maintenance.


IA01 – Create Equipment Task List

IA02 – Change Equipment Task List

IA11 – Create Functional Location Task ListIA12 – Change Functional Location Task List

IA05 – Create General Task ListIA06 – Change General Task List

SummarySummary

You should have understood the concept of

BOM – Bill Of Material

Work Center

Task List

PM PM

Technical ObjectsTechnical Objects

Course ObjectivesCourse Objectives

Understand the concepts of following:

Functional LocationsEquipmentFleet ObjectsProduction Resource ToolsSerial NumberingWarranties Counters and Measuring points

Create Technical objects hierarchy

Manage technical objects.

Course DirectionCourse Direction

Technical Objects

Functional Locations

Equipment

Fleet Objects

Production Resource Tools (PRT)

Serial Numbering

Warranties

Measuring Point

Structure of Technical ObjectStructure of Technical Object

Maintenance Plant

A maintenance plant is a place where operational systems of a company are installed which requires periodic maintenance.

Each manufacturing or maintenance setup will form a separate maintenance plant.

Planning Plant

A maintenance planning plant is the organizational unit where the planning for maintenance are performed.

Each manufacturing or maintenance setup will form as maintenance planning plant.


Technical Objects


Equipment

Fleet Objects


Serial Numbering

Warranties

Measuring Point

Functional LocationsFunctional Locations Functional location

A functional location is a position within the hierarchical structure and represents a location where technical objects can be installed.

Functional Location Structure (FLS)

A logical break down of a plant or section of a plant that allows both operations and maintenance personnel to easily find the correct area of the plant and specific pieces of equipment that require maintenance.

Structure of IND6 (FLS)Structure of IND6 (FLS)

Plant structure is broken into four parts:

AAZZ-NN-ZZZZZ-ZZZZZ

1 2 3 4

Level 1: Plant & Processing AreaLevel 2: Processing Lines / FacilitiesLevel 3: Major Processes / FacilitiesLevel 4: Sub-Processes / Facilities

It is suggested to use standard abbreviations for the naming convention for each level.

Structure Example (FLS)Structure Example (FLS)IND6

Production ofProduct A

IND6-01Line 1

IND6-01-PPS01

Piping System

IND6-01-FPS01Fire Prevention

Systems

IND6-03Line 3

Level 1

Level 3

Level 2 IND6-02Line 2

IND6-01-PTS01 Production system

IND6-01-PTS01-MAC01

Machine 1

IND6-01-PTS01-MAC02

Machine 2Level 4

Functional Location MasterFunctional Location Master

Functional Location Master data contains

General Data – reference data and manufacturer data

Location -- Location data, address

Account data -- Cost center, company code

Structure -- Functional location structure info.

Data links -- Data link to master records. E.g. Measuring point

Functional Location CategoryFunctional Location Category

Initially functional locations and structures are part of PM master data.

The functional location category controls the layout of the functional location master record.

The functional locations can be broken up into the different categories:

Creating Functional LocationsCreating Functional Locations

New functional locations are created when:

A new plant is built

An existing plant is expanded

Functional location can be created by copying from an existing functional location.

Copied details from the existing functional location into the new functional location can be changed.

Functional Functional Location Location MaintenanceMaintenance A functional location will need to be maintained when:

Functional location is activatedMaintenance responsibility changesFinancial responsibility changesFunctional location is no longer required

When several functional locations are to be changed, the Change Functional Locations Using List Editing transaction(IL05) can be used.

If a functional location is no longer required it should be deactivated.


IH01 - Display Functional Location Structure

IL01 – Create Functional Location

IL04 –Create Functional Location using List Editing

IL02 – Change Functional Location

IL05 – Change Functional Location using

List Editing


Technical Objects


Equipment

Fleet Objects


Serial Numbering

Warranties

Measuring Point

EquipmentEquipment

Equipment is an individual physical object.

It is maintained as an independent unit to track maintenance costs and technical history.

Equipment RecordEquipment Record

Equipment record represents physical object in the plant.

Equipment can be installed and dismantled from functional locations.

Maintenance is planned and executed with equipment

Maintenance records are kept against each equipment

Installing & Dismantling of Installing & Dismantling of EquipmentEquipment

Equipment can be installed in the functional location at right level

Equipment can be installed only at ONE location at a time

Installing and dismantling indicates the physical movement of equipment

Measuring point and counter transfers are broken during installation or dismantling

Equipment Record infoEquipment Record infoMaster record contains following information

Equipment general data Equipment location Equipment usage Equipment classification Serial number data Classification Measuring points and counters Warranties

Equipment record can be linked to an asset number

Equipment CategoryEquipment Category

Equipment records can be broken up into the categories.

Example of equipment categories B for Safety K for Electrical F for Fleet E for Instrument M for Mechanical P for Production

Resources & Tools The equipment category controls the

layout of the equipment record. The equipment numbering can be

internal generated numbering.

Equipment ClassificationEquipment Classification

Helps to organize equipment master records and describe them in a structured way.

A class hierarchy will help to assist in the search for equipment classes.

Only required equipment can be classified.

The class can be used to search for equipment master records.

Each class will contain several characteristics.

The characteristics are used to store specific information against the equipment master records.

CharacteristicsCharacteristics

Each class will contain a required characteristics: Example Data Sheet Code Drawing code Instrument Drawing code

Additional characteristics can also be included in the class.

A value should be entered for each of the characteristics.

The characteristic data can be viewed from within the equipment master record.

Equipment StatusesEquipment StatusesUser status and system status helps to manage equipment

System status is always attached to the equipment

User status can be attached to an equipment as optional

E.g. Available status of equipment system status will allow it to install

Equipment DismantlingEquipment Dismantling

Equipment can be dismantled from the functional location when it is required. E.g. removed from the functional location.

Upon dismantling the equipment the following step should be taken into account: Update the account assignment (i.e. cost center) Update the user status (if applicable) Deactivate maintenance plans (if applicable)

A usage period will be created upon dismantling.

The system status will change to AVLB for ‘Available’.

Equipment InstallingEquipment Installing

An equipment can be installed at a functional location or a superior equipment.

Upon installing the equipment the following step should be taken into account:

Update the account assignment (i.e. cost center)

Update the user status (if applicable)

Activate maintenance plans (if applicable)

The system status changes to INST for ‘Installed’.

A usage period is created for the equipment record.

Equipment ScrapingEquipment Scraping When scrapping an equipment the following steps should be

performed.

Delete any task lists, BOM and measuring points.

De-activate maintenance plans (if applicable)Equipment dismantledUpdate the account assignment (i.e. cost

center) Update the user status to SCRP for ‘Scrapped’

All serialized equipment that are to be scrapped should be returned to the warehouse.


IE01 – Create Equipment

IE02 – Install Equipment

IE02 – Change Equipment

IE05 – Change Equipment using List Editing

IE02 – Dismantle Equipment


Technical Objects


Equipment

Fleet Objects


Serial Numbering

Warranties

Measuring Point

Fleet ObjectsFleet Objects

A fleet object is an equipment that moves from one location to another to perform maintenance functions.

Example: ForkliftsTrucks

Fleet ObjectsFleet Objects A fleet object is a special category of equipment.

It has the same functionality as a normal piece of equipment.

Includes additional tabs to record fleet information: Identification details Dimensions Weight specifications Load specifications Engine details Fuel and lubricant details

Need not be installed at a functional location.

Fleet ObjectFleet Object

A fleet object can also be created as a PRT and a work center.

To create a PRT record for a Fleet object, maintain entries in the PRT tab of the Fleet object record.

A fleet object as a work center allows: Scheduling of fleet object Costing

A fleet object as a PRT allows the fleet object to be assigned to an operation within the order.

Creating Fleet ObjectsCreating Fleet Objects

A fleet object master record is created to represent a mobile device that requires maintenance history to be recorded.

A new fleet object master record is created when; A new fleet object is purchased or An existing fleet object replaced.

During the creation of the fleet object it is possible to: Create measuring points and counters Assign warranties

Fleet Object CountersFleet Object Counters

Counters can be used for fleet objects to assist in:

Calculating fuel and oil consumption

Determining replacement or maintenance of object

For each individual fleet object counters can be created using measurement positions.


IE31 – Create Fleet Object

IE02 – Change Fleet Object


Technical Objects


Equipment

Fleet Objects

Production Resource Tools (PRT)Serial Numbering

Warranties

Measuring Point

Production Resource & ToolProduction Resource & Tool

A PRT is a special resource required by a crew to perform a maintenance task.

A PRT could be a special tool.

Production Resource & ToolProduction Resource & Tool

A PRT equipment is a special category of equipment.

It has the same functionality as a normal piece of equipment.

Includes an additional tab for PRT information: Usage details Default values Ability to lock

An equipment PRT can be planned as a requirement against an operation within a maintenance order.

Maintenance can be performed and history recorded for a PRT equipment.

Creating PRTsCreating PRTs

A PRT equipment is created for an object when it needs to be planned within a maintenance order.

PRT not installed at a functional location.

During the creation of the PRT equipment it is possible to: Create measuring points and

counters Assign warranties

Transaction tipsTransaction tips

IE25 – Create PRT Equipment

IE02 – Change PRT Equipment


Technical Objects


Equipment

Fleet Objects


Serial Numbering

Warranties

Measuring Point

Serial NumberSerial Number Serialization is the

assignment of a unique SAP serial number to a Material and Equipment master record.

The Serial number is the common link between Material number and Equipment number.

Equipment SerializationEquipment Serialization

New serial number will be given by warehouse for new material.

Equipment record is created automatically.

The serial number will always stay unique to the equipment


IE02 – Maintain Serialization for Equipment

IQ09 – Display Serial Numbers using List Editing

MMBE – Display Serial Numbers from

Stock Overview


Technical Objects


Equipment

Fleet Objects


Serial Numbering

Warranties

Measuring Point

WarrantiesWarranties

A warranty is given to the customer by a vendor or manufacturer.

This assures to the customer that the product is reliable and free from known defects.

It also assures customer to undertake the responsibility for any defect within stipulated period

WarrantiesWarranties Two types of warranties available:

Inbound -- Vendor / Manufacturer Outbound -- Customer

Both a Vendor/Manufacturer and a Customer warranty can be assigned to an equipment.

A warranty can be assigned to the equipment by:Entering the warranty start or finish

dates directly in the technical object record or

Assigning a master warranty

Warranties that are maintained without a master warranty on the equipment record can only be time based.

Master WarrantyMaster Warranty

To define more complex warranties for an equipment a master warranty can be used.

A master warranty is broken into three parts. Header Item Counter

Master Warranty CountersMaster Warranty Counters Warranty counters are used to define the

conditions and requirements for the master warranty.

Warranty counters can be: Time based Performance based counters Combination of both

If the master warranty contains more than one warranty counter an “and/or” relationship must be entered.

If performance based counters are used within the warranty master the corresponding counters must be first created for the technical object.

Master Warranty (Cont.)Master Warranty (Cont.)

When assigning a master warranty to an equipment a warranty start date must be entered.

Once a master warranty is assigned to an equipment record a warranty check is performed each time a maintenance notification or order is created against the equipment.

The user can then investigate if the maintenance activities are covered by the warranty and take the necessary actions.


IE02 – Maintain Time Based Warranty for Equipment

BGM1 – Create Master Warranty

BGM2 – Change Master Warranty

IE02 – Assign Master Warranty to Equipment


Technical Objects


Equipment

Fleet Objects


Serial Numbering

Warranties

Measuring Point

Measuring PointsMeasuring Points A measuring point is a physical or logical

position for a technical object (Equipment) where a condition can be recorded.

A counter is a kind of measuring point that accumulates performance based readings.

A Technical object (equipment) can have multiple measuring point

Measuring PointsMeasuring Points

Measuring points and counters are created for technical objects to record a condition for the technical object at a given point in time.

Examples of the type of conditions: Temperature as measurement points Flow rate as counters Operating hours as counters

The measuring point or counter defines the location and the specific condition to be recorded for the technical object.

Each measuring point or counter will have its own ID number.

Measuring PointsMeasuring Points

A technical object can have multiple measuring points and counters.

Use of Measuring pointsUse of Measuring points

Measuring points can be used for condition monitoring of a piece of equipment.

Upper and lower limits can be set for a measuring point.

corrective maintenance notification is automatically created, If a measurement reading is outside the tolerance limit.

Counter Measuring PointsCounter Measuring PointsA counter is used to record continuous

values. (e.g accumulative values, run time hours)

Counters can be used in maintenance plans to schedule preventive maintenance.

An annual estimate is entered for a counter.


IK04 – Create Measuring Point for Object

IK05 – Change Measuring Point for Object

IK08 – Change Measuring Points using

List Editing

IK31 – Create Measurement Reading Entry List

SummarySummary

Understood the concepts of following:

Functional LocationsEquipmentFleet ObjectsProduction Resource ToolsSerial NumberingWarranties Counters and Measuring points

Should be able to create Technical objects hierarchy and Manage Technical Objects

Documents

PM Master Data 2. Course Objective Understand the concepts of Bills Of Material (BOM) Work Center Task List Above tasks are divided in to three parts