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Business Consulting Services
SAP PM Module Training
Presentation Title | Confidential | Document ID | Apr 9, 2023 2
PLANT MAINTENANCE SYSTEM
SAP R/3
Presentation Title | Confidential | Document ID | Apr 9, 2023 3
I. MANAGING MASTERS
II. MANAGING MAINTENANCE PROCESSES
III. MANAGING REPORTS
PLANT MAINTENANCE SYSTEM
Presentation Title | Confidential | Document ID | Apr 9, 2023 4
I. MANAGING MASTERS
Presentation Title | Confidential | Document ID | Apr 9, 2023 5
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
CONTENTS OF MAINTENANCE OF MASTERS
• Plant• Main Planner Group• Plant Section• Main Work Center• Cost Center /Internal Order• Category• Company Code• Strategy• UOM
Presentation Title | Confidential | Document ID | Apr 9, 2023 6
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
CONTENTS OF MAINTENANCE OF MASTERS
• Function Location Structure
• Function Location Category
• Plant
Presentation Title | Confidential | Document ID | Apr 9, 2023 7
Functional locations Structure is a hierarchical Presentation of a Tech.
System.
Gives information about how the Technical System is sub divided into
Individual Functional Units.
Individual function Units are defined on the Basis of Process Orientation,
Functions, or any other Special criteria. Each functional location is managed independently in the system, so that you can :
• Manage individual data from a maintenance perspective for the object• Perform individual maintenance tasks for the object• Keep a record of the maintenance tasks performed for the object• Collect and evaluate data over a long period of time for the object
FUNCTIONAL LOCATION STRUCTURE
Presentation Title | Confidential | Document ID | Apr 9, 2023 8
FUNCTION LOCATION STRUCTURE
Description Code
Structure Indicator GIL
Structure Indicator Text GIL Cement Division
Edit Mask AAA-AANN-AAX-AAX-XXX-XXXXX
Hierarchy Levels 1 2 3 4 5 6
Hierarchy Level
Edit Mask Code Description
Level 1 AAA GIL Grasim Industries Limited
Level 2 AANN RC01 Raja shree Cement
Level 3 AAX RC1 Raja shree Cement Unit-I
Level 4 AAX CM1 RC1 Cement Mill-1
Level 5 XXX FEG RC1 Cement Mill -1 Feeding Group
Level 6 XXXX
Example
Presentation Title | Confidential | Document ID | Apr 9, 2023 9
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
CONTENTS OF FUNCTIONAL LOCATION MASTER
• Function Location Structure
• Function Location Category
• Plant
Presentation Title | Confidential | Document ID | Apr 9, 2023 10
FUNCTION LOCATION CATEGORY
Category Description
C Colony Functional Locations
G General Functional Locations
H Hierarchical
M Plant & Machinery F Locations
N Mines Functional Locations
O Office Functional Locations
T Power Generation F. Locations
U Utility Functional Locations
Presentation Title | Confidential | Document ID | Apr 9, 2023 11
Display of Function Location-[IL03]
List Editing of Function Location-[IH06]
Display ( Multi Level) Function Location[IL07]
DISPLAY CONTENTS: Display Action Log
Object Information
NAVIGATE > SAP SCREEN
Presentation Title | Confidential | Document ID | Apr 9, 2023 12
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF MAINTENANCE OF EQPT MASTER
Equipment Category Plant Functional Location Main Planner Group Tech. Object Type Plant Section Main Work Center Cost Center /Internal Order Company Code Class Warranty data
Presentation Title | Confidential | Document ID | Apr 9, 2023 13
Defining Equipment Categories is a facility in SAP/PM to
group the vast variety of Equipments that any manufacturing
Organization can have in their Plant. One of the methods of
grouping similar Equipments is to differentiate them on the
basis of their Use and / or the Function that they perform e.g.,
Electrical Equipment. In GIL, this is the basis of defining
Equipment Category shown in the next two slides
EQUIPMENT CATEGORY
Presentation Title | Confidential | Document ID | Apr 9, 2023 14
CATEGORY
EQUIPMENT EXAMPLES
A AUTOMOBILE CARS/JEEP/MOBILE VAN
C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS
D DUMMY EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR TRANSFER. NOT TO BE USED
E ELECTRICAL EQUIPMENTS MOTORS/TRANSFORMERS/SWITCH GEARS
I INSTRUMENT EQUIPMENTS RTD’S/PROXIMITY SWITCHES/FIELD INSTRUMENTS/PANELS
M MECHANICAL EQUIPMENTS GEAR BOXES/DPC/DBC/BELT CONVEYORS
N MINES EQUIPMENTS SHOVELS/DUMPERS/DRILLING MACHINES
EQUIPMENT CATEGORY
Presentation Title | Confidential | Document ID | Apr 9, 2023 15
CATEGORY
EQUIPMENT EXAMPLES
P PROCESS EQUIPMENTS CYCLONES/HOPPERS
Q QC TEST EQUIPMENTS CUBE TESTING MACHINE / COMPRESSIVE STR MACHINE
R PRODUCTION RESOURCES/TOOLS CRANES
T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER
U UTILITY EQUIPMENTS COMPRESSOR/WATER PUMPS
NOTE:
ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO
TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT
CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.
EQUIPMENT CATEGORY
Presentation Title | Confidential | Document ID | Apr 9, 2023 16
EQUIPMENTS CATEGORY & NUMBER RANGE
Category
DescriptionNumber range
From
Number Range To
M Mechanical Equipments 10000000 19999999
E Electrical Equipments 20000000 29999999
I Instrumentation Equipments 30000000 39999999
P Process Equipments 40000000 49999999
T TPP & DG Equipments 50000000 59999999
N Mines Equipments 60000000 69999999
AAutomobiles Equipments
70000000 79999999
C Civil Objects & General Equipt. 80000000 89999999
S Safety Equipments 90000000 99999999
Q QC Test Equipments 1000000 1999999
Presentation Title | Confidential | Document ID | Apr 9, 2023 17
Technical Object Types are the logical grouping of Objects on the
basis of similarity of function being performed by each one.
Examples :
ME_GEARBOX Gear Box
EL_MOTORS Electrical Motors
ME_FANS Fans
TECHNICAL OBJECT TYPE
Presentation Title | Confidential | Document ID | Apr 9, 2023 18
Plant in which maintenance tasks are planned and executed. In GIL ,
Planning Plant is also a Maintenance Plant. Different Planning Plants in GIL
are :
Aditya Cement
Grasim Cement
Vikram Cement
Rajashree Cement
Grasim South
Birla Super Cement (Hotgi)
Birla Plus Cement (Bhatinda)
PLANNING PLANT
Presentation Title | Confidential | Document ID | Apr 9, 2023 19
MAIN WORK CENTER
Main Work Center is Logical Grouping of all Work Centers, which are
Performing similar nature of Maintenance Tasks/Activities in different
Plant Sections. E.G. Mechanical Main Work Center is a Group of Plant
Maintenance Persons, who are executing Mechanical Maintenance
activities . Different Main Work Centers defined are :
• Mechanical Department
• Electrical Department.
• Instrumentation Department.
• Process Department.
• Civil Department, Etc.
Presentation Title | Confidential | Document ID | Apr 9, 2023 20
Plant Section is a division of Maintenance Plants into Production
Areas.
PLANT SECTION
DescriptionCategory Plant
Packing Plant -1 PP1GC01
Cement Mill -1 CM1GC01
Kiln -1 KL1GC01
Coal Mill -1 CO1GC01
Raw Mill -1 RM1GC01
Presentation Title | Confidential | Document ID | Apr 9, 2023 21
PLANNER GROUP
Planner Group defines the Group of People (Employees) responsible for Planning and Execution of Maintenance Activities in a Particular Plant.
PLANNER GROUP CODIFICATION LOGIC
PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION
MCM = Mechanical + Cement Mill
ECM = Electrical + Cement Mill
ICM = Instrumentation + Cement Mill
Presentation Title | Confidential | Document ID | Apr 9, 2023 22
COST CENTER/ INTERNAL ORDERS
Cost Centers are logical Organizational Units where the costs are incurred for value addition . Costs incurred are ultimately settled to Cost Centers through Orders.
Internal order is nothing but an intermediate cost collector between PM order and cost center. Internal Order will be used in Mines Equipment only.
Cost Center Concept as applied in GIL :
Plant Section = Superior Cost Center
Department = Sub Cost Center in that Plant section
CEMENT MILL
Mechanical ProcessElectrical Instrumentation
Presentation Title | Confidential | Document ID | Apr 9, 2023 23
Creation of Equipment-[IE01] Change of Equipment-[IE02] Display of Equipment-[IE03] List Editing of Equipment-[IH08] Display ( Multi Level)-[IE07]
DISPLAY CONTENTS:
Display of Usage List Display Action Log Display Object Information Installation & Dismantle
NAVIGATE > SAP SCREEN
Presentation Title | Confidential | Document ID | Apr 9, 2023 24
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF CLASS & CHARACTERISTICS MASTERS
Class Type
Class Group
Characteristics Group
Unit of Measure for
Characteristics Master
Presentation Title | Confidential | Document ID | Apr 9, 2023 25
Classes are :
Logical Grouping of Equipments having Similar Functions. Class Mainly Depends on the Main Function / Activity being
Performed by that Equipment. It helps to know the Number of Equipments having the same
Class. Class data will never Change throughout the entire Productive
Life-Cycle of the Equipment. This information can be used for Proper Planning of Spares,
for planned Maintenance & obtaining the History of that Class of Equipments.
CLASS
Presentation Title | Confidential | Document ID | Apr 9, 2023 26
Characteristics are the Specifications or Designed Parameters of Measurement for the Equipments. Ex. Flow of Fan , Gear Ratio of Gear Box.
Combination of Class and Characteristics helps in Precise search of Equipments.
For Example:
Select Gearbox of Particular Make / Ratio. Select Class as Gearbox & Characteristics as Make/ Ratio. Enter
Relevant Values of these Characteristics. System will search & display all Gearboxes satisfying above
Characteristics Values
CHARACTERISTICS
Presentation Title | Confidential | Document ID | Apr 9, 2023 27
CLASS
Class Description
GEARBOX GEARBOX
BUCKETELELVATOR BUCKET ELELVATOR
BALLMILL BALL MILL
BAGHOUSE BAG HOUSE
Class Description
LTMOTOR LT MOTOR
LTFEEDER LT FEEDER
BATTERY BATTERY
BREAKER BREAKER
Mechanical Electrical
Presentation Title | Confidential | Document ID | Apr 9, 2023 28
CLASS AND CHARACTERISTICS GROUPS CODES
Class Group Code DescriptionPM_EQ_ELEC PM Elec. Equipments Specs. Class Group
PM_EQ_GENL PM General Equip. Specs. Class Group
PM_EQ_INST PM Inst. Equipments Specs. Class Group
PM_EQ_MECH PM Mech. Equipments Specs. Class Group
PM_EQ_MINE PM Mine. Equipments Specs. Class Group
PM_EQ_PROC PM Proc. Equipments Specs. Class Group
PM_EQ_TPDG PM TPP & DG Equip. Specs. Class Group
SA_EQ_SAFE PM Safety Equip. Specs. Class Group
Char. Group Code DescriptionPM_EQ_ELEC PM Elec. Equipments Specs.Char. Group
PM_EQ_GENL PM General Equip. Specs. Class Group
PM_EQ_INST PM Inst. Equipments Specs.Char. Group
PM_EQ_MECH PM Mech. Equipments Specs.Char. Group
PM_EQ_MINE PM Mine. Equipments Specs.Char. Group
PM_EQ_PROC PM Proc. Equipments Specs.Char. Group
PM_EQ_SAFE PM Safety Equip. Specs. Char Group
PM_EQ_TPDG PM TPP & DG Equip. Specs. Char. Group
Presentation Title | Confidential | Document ID | Apr 9, 2023 29
Display of Class List [CL03]
Find Object in Class- [CL30N ]
NAVIGATE > SAP SCREEN
Presentation Title | Confidential | Document ID | Apr 9, 2023 30
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF MIC’s MASTER
Plant
Range of Characteristics Value
Presentation Title | Confidential | Document ID | Apr 9, 2023 31
MASTER INSPECTION CHARACTERISTCS
Specific parameters of an Equipment for Calibration
Parameters to measure whether Equipment is performing its function
The Parameter driving / governing Equipment performance/Output is
within acceptable limits.
Example: Mili-amperes / Mili-volts for weigh Feeder
Presentation Title | Confidential | Document ID | Apr 9, 2023 32
Find out The Maintenance Inspection Characteristics prepared-[QS24]
NAVIGATE > SAP SCREEN
Presentation Title | Confidential | Document ID | Apr 9, 2023 33
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF WORK CENTER MASTER
Plant
Work Center Category
Control Key
Cost Center
Work Dimension - Time
Work Unit
Presentation Title | Confidential | Document ID | Apr 9, 2023 34
WORK CENTER
Work Center is a Person/Group of Persons, who perform Maintenance Activities.
Work Center Category
Each Department will have two categories, Permanent and Contractor.
Category Description
0021 Mechanical Permanent
0022 Mechanical Contractor
Example : M1F1W3K, MC1F1W3K etc.
Codification Logic :
M1F1W3K = Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi
MC1F1W3K = Mech. Contractor / 1 Fitter /1Welder / 3 Khalasi
Presentation Title | Confidential | Document ID | Apr 9, 2023 35
NAVIGATE > SAP SCREEN
Work Center List-[IR03]
DISPLAY CONTENTS: Relevant Number for Permanent and Contractor Work centers
for your department. Different combinations of Skills.
Presentation Title | Confidential | Document ID | Apr 9, 2023 36
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF MEASURING POINT MASTER
Equipment Master
Function Location Master
Category of Measuring Point
Characteristics
Unit of Measures
Presentation Title | Confidential | Document ID | Apr 9, 2023 37
It is a Measurement characteristic/Parameter attached to an Equipment
Describe the Physical and/or Logical Locations of Equipment
at which a Condition / Parameter is to be measured.
Measuring Point will be always for an Equipment or FL or assembly
but Generally for Equipments.
Measurement readings are taken for an Equipment at regular
interval to know the Condition at that time.
MEASURING POINT
Presentation Title | Confidential | Document ID | Apr 9, 2023 38
Measuring Point is also Used as Counter where values Measured by a Measuring Point can be summed up during a time period for monitoring and control .
Example:
Running hours of Any Equipment
Lubrication Consumption.
MEASURING POINT Continued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 39
NAVIGATE > SAP SCREEN(MP)
Creation Of Measuring point [IK01 ]
Change / Display Of Measuring Point [IK02/ IK03]
Display List Editing-[IK07]
Create Entry List-[IK31]
Collective entry of measuring document-[IK34]
DISPLAY CONTENTS:
Transfer of Measuring point
Presentation Title | Confidential | Document ID | Apr 9, 2023 40
MAINTENANCE MASTERS
BASIC MASTERS
1. Function Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF TASK LIST MASTERS
Group Coding
Counter
Planning Plant
Maintenance Strategy
Work Center
Set of Operations
MIÇ’s
Presentation Title | Confidential | Document ID | Apr 9, 2023 41
TASK LIST
A Set of Activities to be Performed on an Equipment or Functional
Location.
Three types of Task Lists : Functional Location Task List[T] Equipment Task List[E] General Task List[A]
Presentation Title | Confidential | Document ID | Apr 9, 2023 42
seq Codification Logic for defining Task List Group - It has to be Planning Plant / Maintenance Specific
1 XX GIL Plant Short Code:
RC = RC01, GS = GS01, GS = GS01, GC = GC01, BS = BS01.
2 X Discipline:
E = Electrical, M = Mechanical, I =Instrumentation, P = Process, N = Mines, T = TPP, Q = QC,S = Safety
3 XX Equipment Short "Equipment Class Code":
GB = Gear Box, BF= Bag Filter, BC = Belt Conveyor, AT = Analyzer, MO= DC Motor, etc
4 X Equipment Class Code Type( application) :
GB Gear Box Helical; Radial; BE-Bucket Elevator Belt/ Chain
5 XX Type of Maintenance Task List:
PM=Preventive Maintenance , AM = AMC Tasks, CA= Calibration ; SD = Shutdown , IN = Inspection (attribute/Value EN-Environment;) J-Jishu Hozen ( General Inspection ) ZX- Safety
Example: GCMGBHPM GCM-GBH-PM 1M Checks
GCEMODPM GCE-Motor-DC-PM 3M Checks
TASK LIST CODIFICATION
Presentation Title | Confidential | Document ID | Apr 9, 2023 43
Set of Predefined Prefixed Time Intervals ( Called Packages) grouped
at Which Preventive Maintenance Activities can be taken Up.
These Maintenance Strategies can be selected By User to carry out Maintenance Activities depending Upon :--
Age of Equipment Design of Equipment Importance of Equipment in Production Process Maintenance Practices of Organization.
MAINTENANCE STRATEGY
Presentation Title | Confidential | Document ID | Apr 9, 2023 44
GILDAY -- Frequencies Specified in “ GILDAY”
Are 1W / 2W / 1M / 3M / 6M / 1Y
GILMON-- Frequencies Specified in “ GILMON”
Are 6M/ 1Y/ 2Y/ 5Y
MINEHR -- Frequencies Specified in “ MINEHR”
Are 100HR/ 300HR / 350HR/ 400HR
PERFHR -- Frequencies Specified in “ PERFHR”
Are150HR / 250HR / 500HR/ 1000H
MAINTENANCE STRATEGIES Continued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 45
GILDAY: Strategy is Used for Frequencies of Check Up to 6M.
GILMON: Strategy is Used for Frequencies of Checks More than 6M.
MINEHR: Strategy is Used For MINES Preventive Maintenance Planning.
PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance
Planning.
APPLICATION: Continued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 46
MAINTENANCE PACKAGEStrategy GILDAY
Cycle Length UOM Maintenance Cycle Text Cycle Short Text
7 DAY Weekly (1 Week ) 1W
14 DAY Fortnightly (2 Weeks ) 2W
28 DAY Monthly ( 4 Weeks ) 1M
84 DAY Quarterly ( 12 Weeks ) 3M
168 DAY Half yearly ( 24 Weeks ) 6M
336 DAY Yearly ( 48 Weeks ) 1Y
Strategy GILMON
Cycle Length UOM Maintenance Cycle Text Cycle Short Text
6 MON Half yearly 6M
12 MON Yearly 1Y
24 MON 2 Yearly 2Y
48 MON 5 Yearly 5Y
Presentation Title | Confidential | Document ID | Apr 9, 2023 47
Strategy MINEHR
Cycle Length UOM Maintenance Cycle Text Cycle Short Text
96 HR 100 Running Hours ( 96 Hrs) P1
312 HR 300 Running Hours ( 312 Hrs) P2
360 HR 350 Running Hours ( 360 Hrs) P3
408 HR 400 Running Hours ( 408 Hrs) P4
504 HR 500 Running Hours ( 504Hrs) P5
1008 HR 1000 Running Hours (1008 Hrs) P6
1512 HR 1500 Running Hours (1512 Hrs) P7
2016 HR 2000 Running Hours (2016 Hrs) P8
2496 HR 2500 Running Hours ( 2496 Hrs) P9
3000 HR 3000 Running Hours ( 3000 Hrs) 1P
MAINTENANCE PACKAGEContinued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 48
Strategy PERFHR
Cycle Length UOM Maintenance Cycle Text Cycle Short Text
144 HR 150 Running Hours ( 144 Hrs.) P1
240 HR 250 Running Hours ( 240 Hrs.) P2
504 HR 500 Running Hours ( 504 Hrs.) P3
1008 HR 1000 Running Hours (1008 Hrs) P4
2496 HR 2500 Running Hours (2500 Hrs) P5
4032 HR 4000 Running Hours (4032 Hrs) P6
8064 HR 8000 Running Hours (8064 Hrs) P7
12096 HR 12000 Running Hours (12096 H) P8
16128 HR 16000 Running Hours ( 16128 H P9
24192 HR 24000 Running Hours ( 24192 H 1P
32256 HR 32000 Running Hours ( 32256 H 2P
Continued..MAINTENANCE PACKAGE
Presentation Title | Confidential | Document ID | Apr 9, 2023 49
Display Task List-[IA07] List Editing Task List-[IA09]
DISPLAY CONTENT: Find Task Lists in your Planner group.
NAVIGATE > SAP SCREEN
Presentation Title | Confidential | Document ID | Apr 9, 2023 50
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF MAINTENANCE ITEM MASTER
Equipment /Function Location
Master
Task list Master
Strategy
Presentation Title | Confidential | Document ID | Apr 9, 2023 51
Maintenance Item describe Preventive Maintenance Tasks
to be performed on an Equipment at Predefined Interval
Maintenance Item = Equipment + Task List with set of operations
with Maintenance Package
MAINTENANCE ITEM
Presentation Title | Confidential | Document ID | Apr 9, 2023 52
MAINTENANCE MASTERS
BASIC MASTERS
1. Functional Locations
2. Equipment Master
3. Class & characteristics
4. MIC’s
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan
BASIC CONTENTS OF MAINTENANCE PLAN MASTER
Maintenance Item Master
Strategy
Scheduling parameter
Presentation Title | Confidential | Document ID | Apr 9, 2023 53
Maintenance Plan is the Scheduling of Task List attached to an
Equipment (Maintenance Item ) on Time Scale ( According to
Factory Calendar ) or Performance scale ( According to Counter
i.e. Number of Hours).
Plan = Maintenance Item + Scheduling Parameters
MAINTENANCE PLAN
Presentation Title | Confidential | Document ID | Apr 9, 2023 54
TOLERENCE: ( 50% )
It is the difference between planned date and TECO date ,given in %age for deciding whether maintenance cycle should be shifted or not, considering the gap between planned date and TECO date.
Shift factor” will be effective only if difference between planned date and TECO date is more than 50% of smallest interval (smallest package) , either + or – side. If difference between planned date and TECO date is less than 50% of smallest interval (smallest package) , there will be no shift. For GILDAY , it will be + / - 3.5 days , as minimum frequency is 1w. For GILMON it will be +/- 3 months as min freq is 6M.
SHIFT: 100% .
If condition given in “Tolerance” is true it will shift the maintenance cycle by : given shift % x difference between planned date and TECO date .i.e. Actual delay
MAINTENANCE SCHEDULING PARAMETER
Presentation Title | Confidential | Document ID | Apr 9, 2023 55
It indicates that an advance intimation of planned maintenance will be given by 0.5 x minimum frequency of strategy selected through order generation .
FOR GILDAY :
1W Being minimum frequency , you will get weekly order 3.5 days
in advance if call horizon is 50%.
CALL HORIZON 50%
MAINTENANCE SCHEDULING PARAMETERContinued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 56
II. MANAGING MAINTENANCE PROCESSES
Presentation Title | Confidential | Document ID | Apr 9, 2023 57
MAINTENANCE PROCESSES
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of Notification• Creation of Orders• Execution of Orders• Confirmation of Orders• Technical Confirmation of
Orders• Creation of Purchase Request• Creation of Purchase Orders• Service Entry Sheets• Creation of Measuring Points
& Measuring Documents• Installation / De-installation of
Equipments
Presentation Title | Confidential | Document ID | Apr 9, 2023 58
1. PREVENTIVE MAINTENANCE PROCESS
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF PREVENTIVE MAINTENANCE PROCESS
• Selection of Orders
• Execution of Orders
• Confirmation of Orders
• Technical Completion of
Orders
Presentation Title | Confidential | Document ID | Apr 9, 2023 59
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Selection of Orders
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Selection of Order
Go to T. Code - IW39
Flag Outstanding & In process check box
Enter Order Type PM01
Enter Maintenance Plant
Enter Planner group for Order
Execute by clicking button
Order list of relevant section Appears
Enter Period ( Date from…..to ……)
Enter Status exclusive in Multiple Selection
Select from Drill Down
CRTD, CNF ,TECO & CLSD
Select from Drill Down
H/L TO ORDER TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 60
ORDER TYPES
PM01 --- PREVENTIVE MAINTENANCE ORDERS
• These Orders are Planned by SAP System
• User can not generate PM Work Order for this Order Type externally.
• This Order type will help User to find out Cost of Preventive Maintenance exclusively for his Plant section/Planner group.
• User will be able to compare Cost Of Preventive Maintenance vis-à-vis Breakdown and Shutdown Maintenance.
• User will be able to judge the effectiveness of Preventive Maintenance Plans by this Order Type.
• Order Numbering is blocked for this Order
• User will get Preventive Maintenance Orders under Maintenance Activity Type - PVM , Annual Maintenance Contract Orders under Maintenance Activity Type - AMC and Inspection Orders under Maintenance Activity Type INW
Presentation Title | Confidential | Document ID | Apr 9, 2023 61
PM02: BREAKDOWN MAINTENANCE ORDERS
•This Order Type is exclusively for Breakdown registration of Equipments
•This Order Type indicates Unplanned stoppage in Production Process
• In addition to consumption of Recourses like Men , Machine , Material , Production loss is also associated with this type of Order .
• User can further segregate the breakdowns of Equipments under Warranty / Insurance from other Breakdowns.
PM03: SHUTDOWN MAINTENANCE ORDERSThis Order Type indicates • Annual Shutdowns ( Maintenance Activity Type: SDM)
• Planned Weekly,Fortnightly,Monthly Stoppages ( Maintenance Act. Type : WFM)
• Opportunity Based Maintenance (Maintenance Activity Type: OPP)The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be booked under MAT- SDM.
Continued..ORDER TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 62
PM03: SHUTDOWN MAINTENANCE ORDERS
• Only Planned Weekly,Fortnightly,Monthly Stoppages will be booked under Maintenance Activity Type – WFM• Other Maintenance jobs not planned but undertaken because of availability of Opportunity are booked under MAT-OPP.
PM05: CALIBRATION MAINTENANCE ORDERS
• This Order Type is applicable for Calibration of Equipments• These Orders are Planned by System . However , User can also raise Order externally , if required for unplanned Calibration jobs.• This Order Type has MAT- CAL .
PM06 : CORRECTIVE MAINTENANCE ORDERS
• The jobs covered under this Order Type are of 2 types: Corrective Actions suggested under WHY-WHY Analysis to avoid recurrence of Breakdown will be covered under Maintenance Type – WHY .
Continued..ORDER TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 63
PM06 : CORRECTIVE MAINTENANCE ORDERS• Other Maintenance Jobs of Corrective Nature e.g. Maintenance Requests from other departments , Removal of Abnormalities/Defects, Removal of Unsafe Conditions where Breakdown has not occurred will be covered under MAT- CRM
PM07 --- CONDITION BASED MAINTENANCE ORDERS• This Order Type is applicable for jobs planned on the basis of Condition of Spares. E.g. Replacement of Worn Out Chain/ Worn-out Hammers etc
• MID , being Condition Monitoring Department , will use this Order Type for advising repair /
replacements on the basis of Condition E.g. Hardness/Thickness/Vibrations etc
PM08 --- GENERAL MAINTENANCE ORDERS• This Order Type is applicable for UNDEFINED jobs NOT FALLING under above categories and not related to Equipment. E.g. Leakage of Water Tap in Administration Building garden.• These are of Minor nature Repair Jobs.
•This Order Type should not be used unless it satisfies above condition
Continued..ORDER TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 64
PM09: REPAIR MAINTENANCE ORDERS
There are Four different Activity Types or jobs covered under this category. They are:
• Work Shop jobs should be registered under MAT – RWS• Rewinding jobs should be registered under MAT - REW• Tyre Retreading jobs should be registered under MAT – RET• External Repair jobs should be registered under MAT – RVN
PM10: IMPROVEMENT/MODIFICATION ORDERS
• All jobs of Improvements and Modifications in Maintenance (Reliability MTTR/MTBF/Maintainability/Availability) are covered under Maintenance Activity Type – IMO
• Suggestions given by Consultants/Experts/Other Units/ Other sources like Websites, Manuals, Magazines etc are covered under Maintenance Activity Type – CON.
PM11: CAPEX/BLOCK ORDERS
• All Work Orders raised for Project Work are covered under this Order Type and MAT-CAP
PM12 --- CIVIL MAINTENANCE ORDERS
• All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/ Foundation etc are covered under this Order Type and MAT-CIV
Continued..ORDER TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 65
Order Type Description Order Activity Type
PM01 Preventive Maintenance Order PVM,AMC,INW
PM02 Breakdown Maintenance Order BDM,WAR,INS
PM03 Shutdown Maintenance Order SDM,OPP,WFM
PM05 Calibration Order CAL
PM06 Corrective Maintenance Order CRM,WHY
PM07 Condition Based Maintenance CBM
PM08 General Maint Order GEN
PM09 Repairs Order RWS,RVN,RET,REW
PM10 Improvement/Modification Order IMO.CON
PM11 Capex / Block order CAP
PM12 Civil Maintenance Order CIV
QCAL QC Insp./ Calibration Order CAL
MAINTENANCE ACTIVITY TYPES IN PM ORDERS
Presentation Title | Confidential | Document ID | Apr 9, 2023 66
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Selection of Orders
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Selection of Order
Go to T. Code - IW39
Flag Outstanding & In process check box
Enter Order Type PM01
Enter Maintenance Plant
Enter Planner group for Order
Execute by clicking button
Order list of relevant section Appears
Enter Period ( Date from…..to ……)
Enter Status exclusive in Multiple Selection
Select from Drill Down
CRTD, CNF ,TECO & CLSD
Select from Drill Down
H/L TO ORDER TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 67
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Move to SAP Screen
Select desired order
Presentation Title | Confidential | Document ID | Apr 9, 2023 68
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Go to Operation TAB and Change operations etc if reqd
Select operation & Go to Component TAB if Material Required
Select required Component
Enter reqd Qty , Item category, Storage Location & Batch
Enter number of Selected Order
Go to T. Code - IW32
Release PM01 Type Selected Order
Order status will be changed to REL from CRTD
Execution of Orders
Enter Start Date & Time
Come to Header data Tab
Presentation Title | Confidential | Document ID | Apr 9, 2023 69
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
End date & time will be changed by system
Determine cost by clicking
Save the Order
Move to SAP Screen
Schedule Order by Clicking
Presentation Title | Confidential | Document ID | Apr 9, 2023 70
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Selection of Orders
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Confirmation of Order
Go to T. Code – IW44
Select Header Menu Confirmation
Select “via operation list” in Confirmation Menu
Enter Order type
Enter Planner group
Select from Drill Down
Selection of operation list appears
Enter Plant
Enter Status Exclusive in Multi Selection List
CRTD, CNF , TECO & CLSD
Enter Reference date
Presentation Title | Confidential | Document ID | Apr 9, 2023 71
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
All Planning data of operations defaulted from relevant Orders
Flag Final confirmation, Clear all Res & No remaining work
Enter Start Date & Time
Enter End Date & Time
Select All Operations
Click All Actual Data on Header Tool bar
All relevant Orders with Operations will be copied on main screen
Enter Actual Work Center Qty
Execute by clicking button
Presentation Title | Confidential | Document ID | Apr 9, 2023 72
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Enter Confirmation Text
System will calculate Actual Duration
Save Confirmation by clicking
Move to SAP Screen
Enter Actual Duration
Presentation Title | Confidential | Document ID | Apr 9, 2023 73
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of
Orders
CRTD, REL , TECO & CLSD
Select from Drill Down
Technical Completion of Order
Go to T. Code - IW32
Flag In process check box
Enter Order Type PM01
Enter Maintenance Plant
Enter Period (Date from…to…)
Enter Status exclusive in Multiple Selection
Selection of Order Screen appeared
Enter Planner group for Order
Execute by clicking button
Presentation Title | Confidential | Document ID | Apr 9, 2023 74
1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Confirmation of
Orders Click Settlement Rule button
Click Flag of Technical Completion
Enter / change cost center & give % if required
Order Main Header Screen Opens
Order list of relevant section Appears
Select order and click
Enter Reference Date & Time
Click Enter Button
Order is Technically Completed & System Status Changed to TECO
Move to SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 75
2. BREAKDOWN MAINTENANCE PROCESS
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF BREAKDOWNMAINTENANCE PROCESS
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Presentation Title | Confidential | Document ID | Apr 9, 2023 76
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Enter Notification Type
Do not Enter Notification Number
Go to T. Code – IW21Create Notification
Enter Notification Description
Enter Equipment / FL / Assembly (as required)
Enter Reported By (Name)
Creation of M2 Notification
H/L TO N/F Types
System Generated
Notification Tab Screen Appears
Manual Process
Select from Drill Down
Click Enter Button
Presentation Title | Confidential | Document ID | Apr 9, 2023 77
M1 --- MAINTENANCE REQUEST
This Notification type indicates a request made by Customer department to his Supplier/Service Provider. E.g Request made by Raw Mill Mechanical for repair of Gear Box shaft on Workshop.
This includes all types of jobs of Maintenance/Repair/Service requests made by User on Service Provider EXCEPT Malfunction/Breakdown.
M2 --- MALFUNCTION/BREAKDOWN
This Notification Type is exclusively for information regarding Breakdown of EquipmentsThis Notification is raised generally by Production on relevant Maintenance Department as a FIR of Unplanned stoppage in Production Process.However , anybody can raise this Notification if it satisfies above condition.
NOTIFICATION TYPESContinued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 78
M3 --- UNSAFE CONDITION/ACCIDENT
• This Notification is an information from any department including Safety regarding prevailing Unsafe/ Hazardous Condition which is dangerous and may cause damage to Property/Human being / Environment /Surroundings etc , to the relevant department responsible for such condition for necessary corrective action.
M4 --- ABNORMALITY RECORD
• This notification is raised to register 7 types of Basic Defects in Equipments. These defects are revealed through Daily Check List/ Inspection/Plant Round Satisfies the WCM requirement to monitor 7 type of basic defects which are responsible for Breakdown , if not corrected in time.
NOTIFICATION TYPESContinued..
Presentation Title | Confidential | Document ID | Apr 9, 2023 79
M5: RECOMMENDATION/IMPROVEMENT
•This Notification is generated by User for any improvement/development to be implemented .• The source for Improvement/Modification/Development in Reliability/ Availability /Maintainability may be WHY-WHY Analysis, Experts/Consultants recommendation/Other Units/KIP’s etc• The number of such Notifications will be an indicator of improvements done by User • These notifications will give List of Improvements done by User which is required by WCM or for sharing with other Units.
M6 --- WORK REQUEST-WORKSHOP
• This notification is raised by User on workshop requesting its services for Repair/Machining/Replacement of Spares/Assembly/Equipment etc.
Continued..NOTIFICATION TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 80
M7: GENERAL NOTIFICATION.
•Notification which does not fall in any of the conditions mentioned above may be raised in this type.•This type of Notification should not be used as far as possible as it will affect history/vital information about Equipments.
M8: MEASURING POINT ERROR
•This notification is raised by the SAP system automatically whenever the Parameter defined as a Measuring Point deviates from its Standard Value or goes beyond its Acceptable Permissible Value.
Continued..NOTIFICATION TYPES
Presentation Title | Confidential | Document ID | Apr 9, 2023 81
Notification Types
Notification Type Description Number Ranges From -ToM1 Maintenance Request 1000000000 to 1999999999M2 Malfunction, B/Down 2000000000 to 2999999999M3 UnsafeCond./Accident 3000000000 to 3999999999M4 Abnormality Record 4000000000 to 4999999999M5 Recommendation 5000000000 to 5999999999M6 Work Request- W.Shop 6000000000 to 6999999999
Presentation Title | Confidential | Document ID | Apr 9, 2023 82
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Enter Notification Type
Do not Enter Notification Number
Go to T. Code – IW21Create Notification
Enter Notification Description
Enter Equipment / FL / Assembly (as required)
Enter Reported By (Name)
Creation of M2 Notification
H/L TO N/F Types
System Generated
Notification Tab Screen Appears
Manual Process
Select from Drill Down
Click Enter Button
Presentation Title | Confidential | Document ID | Apr 9, 2023 83
2. BREAKDOWN MAINTENANCE PROCESS
All information Defaulted from equipment master
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Go To Location Data Tab
Release & Save the Notification
If Reqd Enter Long Text
Flag breakdown check box
Main Work center/ Planner Group etc Defaulted & can be Changed If Required
Naviaget >SAP Screen
In case of Main Plant, M2 Type Notifications will be Generated by System thru breakdown entry made by CCR
Enter Code of STD TEXT Attached
Popup Massage of warranty Prompts
If equipment Under warranty
Presentation Title | Confidential | Document ID | Apr 9, 2023 84
2. BREAKDOWN MAINTENANCE PROCESS
Select from Drill Down
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Flag check box Outstanding or In process (as Reqd)
Enter Notification Date
Go to T. Code – IW28 Selection of Notification
List of Notifications Appears as per Selection Criteria
Select relevant Notification
Selection of M2 Notification
Enter Maintenance Plant
Enter Planner group
Click Enter Button
Click on Details Button
Navigate. SAP Screen
Notification Change Screen Appears
Presentation Title | Confidential | Document ID | Apr 9, 2023 85
2. BREAKDOWN MAINTENANCE PROCESS
Select from Drill Down
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
M2 Notification selected in Changed Mode as explained in pervious sheet
Further process of order will remain same as explained in process “1. Preventive Maintenance”
Enter PMActType BDM & click continue button & save
Create Order Popup Screen Appears with Defaulted data from notification
Creation of PM02 Type Order from Notification
Click Create button
of Order Tab
Breakdown Order Created
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 86
2. BREAKDOWN MAINTENANCE PROCESS
Process of Selection of Order, Execution of Order, confirmation& TECO will be similar to processes explained in process “1. Preventive Maintenance”
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Presentation Title | Confidential | Document ID | Apr 9, 2023 87
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
M2 Notification selected in Changed Mode as explained in pervious Process
Next Popup screen Database selection for SAP script text
On Insert Text screen Flag Expand immediately , enter Text ID – ST & click on dropdown of Text Name field
Insert Text popup screen appears.
Execution of M2 Notification (Order not generated)
To Attach Std Text Go to Effect field & select relevant code of Std Text
Select from Drill Down
Select from Drill Down
Execute Popup screen Database selection for SAP script text without entering any data
Presentation Title | Confidential | Document ID | Apr 9, 2023 88
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Select malfunction& downtime tab and Enter down time end Date &Time.
Desired Standard Text Get copied in long text. Complete it & go back to main screen
Now popup screen Insert Text appear again with text attached. Click Continue Button
Next Popup screen Find SAP script text will appear. Select relevant text & click continue button
Select from Drill Down
Navigate> SAP Screen
Click Complete Flag and complete Notification
Presentation Title | Confidential | Document ID | Apr 9, 2023 89
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Select status by flagging and execute
Enter Date Range (From...To…)
Go to T. Code -- ZRPM-WHY
Create Why Why Analysis Sheet
Enter Plant , Plant Section & Planner group
List of Notification appears (as per selection criteria)
Select relevant notification & double click it
Why Why Analysis screen Appears
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 90
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Enter Observations
Flag YES box to actual Cause
Enter Object Code
Enter all Possible Causes (Possible reasons)
Enter Analysis In Why Why Field
Enter Rectification carried out
Enter Recommendations
Enter Damage Code
Enter Responsible person and Tar Date for Recommendations
Select Document Attached - Say 2
Select from Drill Down
Select from Drill Down
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 91
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Navigate> SAP Screen
Change Why Why Analysis
Next procedure of Standard text shall be similar as explained in Process “ Execution of M2 Notification”
Click Complete Flag and Complete Notification
Save why-why Analysis
Go to Main screen of selected Notification’s why why analysis
Click “Put in Process” Flag
Change Why Why analysis data as per requirement
Save changed why-why Analysis
Go to T. Code – ZRPM_WHY
Presentation Title | Confidential | Document ID | Apr 9, 2023 92
3. SHUTDOWN MAINTENANCE PROCESS
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 - Shutdown
Orders
• Selection of PM03 - Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Presentation Title | Confidential | Document ID | Apr 9, 2023 93
3. SHUTDOWN MAINTENANCE PROCESS
Enter Equipment Number
Equipment selection screen appears
Equipment Category - M
Enter plant Section
Enter Planner Group
Enter Order Type - PM03
Go to T. Code – IW31
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 - Shutdown
Orders
• Selection of PM03 - Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Report of Shutdown Planning
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Creation of Shutdown Order
Enter Equipment Class (Optional)
Maintenance Plant
Click Execute Button
Select from Drill Down
By Drill Down go to selection screen
Select from Drill Down
Select from Drill Down
Select from Drill Down
Select from Drill Down
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 94
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 - Shutdown
Orders
• Selection of PM03 - Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Enter Order Description
Go to Header data Tab & Enter PMActTYPE - SDM
Enter Relevant Work Center
Select Desired Equipment & click . Equipment entered in
field
Go to Operation Tab and Enter Operations as required
Enter Relevant Control key
Enter Planning Plant & Enter
Create Shutdown Maintenance Order : Central Header Screen appears
Pl Refer Next Slide
Better to Create Separate Order for PMIN & PMEX Control key
Select from Drill Down
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 95
Enter Cost Element & Press Enter
Popup screen External Processing Operation appears
Select Material Group ( S524 For External Services) & Pur. Group
Go to service tab & Select Desired Services from Service Master or write Description only & Enter Required Quantity
Select Operations
Activity type Defaulted
Select Operation & Go to Component TAB if Material Required
Enter WC Qty and Cal.Key
Enter Work or Duration
After Assigning Control Keys PMIN PMEX
Enter required Material, qty, S.Loc (see stock) & Batch
Click Gen Data Button & Get Reservation Number on comp detail screen & come back
Click on External Button
External Processing operation Appears
Enter Vender , tracking No & click
Select from Drill Down
Again Go to Operation screen Enhancement Button and enter Field key – ZPM0001, Position
Select from Drill Down
Select from Drill Down
Select from Drill Down
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 96
For Release Order Press Icon
Save Order by click button
Click scheduling & determine cost button
Navigate> SAP Screen
Create Purchase Requisition screen appears. Enter Dept and Press Enter
Enter Cost Element & Press Enter
Repeat above three steps for Next Operation's
Go to Header Screen & Click Determine cost button
For Release Order Press Icon
Save order by click button
You can See PR No Thru GEN data->Act data Tab
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 97
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 - Shutdown
Orders
• Selection of PM03 -
Shutdown Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Report of Shutdown Planning
• Execution of Orders
• Confirmation of Orders
• Technical Completion of
Orders
Process of Selection of Order, Execution of Order, confirmation & TECO will be similar to processes explained in process “1. Preventive Maintenance”
Presentation Title | Confidential | Document ID | Apr 9, 2023 98
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 - Shutdown
Orders
• Selection of PM03 - Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Enter Order type
Enter Main work center
Enter Plant Section
Enter Planner Group
Flag Outstanding & In process Order
Go to T. Code – IW49N
Report1. of Shutdown Planning
Maintenance Plant
Display order & Operation: selection of order & Operation screen appears
Enter Period (dates)
Select from Drill Down
Select from Drill Down
Select from Drill Down
Select from Drill Down
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 99
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 - Shutdown
Orders
• Selection of PM03 - Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Click Execute Button
Report of Order with Operation etc Appears
View Reports with Relevant Layout selection
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 100
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 -Shutdown
Orders
• Selection of PM03 -Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Flag outstanding & In process
Click Multiple Selection of Order Field
Enter Plant Section
Material availability Information screen
Go to IWBK – Material Availability Check (for orders)
Report 2 of Shutdown Planning (MATERIAL)
Maintenance Plant
Enter Period (dates)
Select from Drill Down
Enter Order Type- PM09
Click Multiple selection button
Select from Drill Down
Select from Drill Down
Enter Planner Group Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 101
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 -Shutdown
Orders
• Selection of PM03 -Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Paste Selected Orders & execute
Click Execute Button
Screen of “Availability list of Materials for Operations” will appears
You will reach back to main screen of Material availability Information
Go to back to Multiple selection screen & Execute
Click execute button again
Report of Order with Operation etc Appears
On This Screen You Will Get Order wise Materials with Stock Availability status Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 102
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 -Shutdown
Orders
• Selection of PM03 -Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order (For Contractors)
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Creation of Direct Purchase Order (For Contractors)
Go to T. Code ME21N –Create Purchase Order
Select Type of Purchase Order
Go to item overview Tab and Enter Account Assignment – K and Item category - D
Enter Material Group , Plant , tracking number (Employee) and Department (planner group)
Enter Vendor Code Select from Drop Down thru Vendors : Purchasing
Enter Purchase Organization, Purchase Group & Company Code
Enter Short text of Services
Select from Drop Down
Select from Drop Down
Select from Drop Down
Select from Drop Down. Search Tracking number thru “Vendor by Company code”
Presentation Title | Confidential | Document ID | Apr 9, 2023 103
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 -Shutdown
Orders
• Selection of PM03 -Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order (For Contractors)
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Go to Account Assignment Sub Tab and Enter G/L Account number and Cost center
Correct Entries If error massage other wise Save the order
Check entries by Clicking Button
Navigate> SAP Screen
Go to Item Tab and Enter Services number , Qty
Select from Drop Down
Select from Drop Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 104
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring Document &
Auto Notification
• Creation of Entry List
• Measuring Document Thru Entry list
• Selection of M8 type Notification
• Creation of Corrective Maintenance
Order Thru Notification
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
4. CONDITION BASE MAINTENANCE PROCESS
Presentation Title | Confidential | Document ID | Apr 9, 2023 105
3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS
• Creation of PM03 -Shutdown
Orders
• Selection of PM03 -Shutdown
Orders
• Report of Shutdown Planning
• Creation of Direct Purchase
Order (For Contractors)
• Creation of Direct Purchase
Request (Indent)
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
Creation of Direct Purchase Requisition (For Spare)
Go to T. code ME51N -Create PR
Enter PR Type & Header note
Account Assignment Type – U & Item Category leave Blank
Enter Material & Reqd Qty
Enter Del date , Plant & Tracking number (planner group)
Check entries by Clicking Button
Correct Entries If error massage other wise Save the Purchase request
Navigate> SAP Screen
Select from Drop Down
Select from Drop Down
Select from Drop Down
Select from Drop Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 106
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type
Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Select & enter Equipment number
Select Relevant Measuring Point Category (Except L & F)
Do not flag MP as counter for CBM
Select Measuring Point Object - IEQ
Go to T. Code - IK01 -Crete Measuring Point
Creation of Measuring Point
Click on Enter Button
Write Measuring Position & Description
Presentation Title | Confidential | Document ID | Apr 9, 2023 107
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type
Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Main screen appears. Now click on Save button to save MP
Enter Upper range limit & Lower range limit
Click on Enter Button
Navigate> SAP Screen
Go to Additional data Button header tool bar
Enter relevant Characteristic (UOM & decimal Place defaulted)
Presentation Title | Confidential | Document ID | Apr 9, 2023 108
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Navigate> SAP Screen
Selection of Measuring Point
Measuring point list appears
Select relevant Measuring point
Enter Characteristics & MP Category
Go to T. Code - IK07 – Display measuring Point : Measpoint Selection
Click Execute Button
Presentation Title | Confidential | Document ID | Apr 9, 2023 109
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto Notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Creation of Measuring
Document
Enter MeasRdg as taken from site
A Massage Appears In case Reading is Outside range
Enter Measuring Point (as selected)
Go to T. Code – IK11 - Crete Measuring Document
Again Click on Enter Button
Main screen of M8 type Notification Generates Automatically
Again Click on Enter Button
Again Click on Enter Button
Presentation Title | Confidential | Document ID | Apr 9, 2023 110
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto Notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Navigate> SAP Screen
A massage comes for Measuring document Created
Enter Reported by & click Enter button
An Auto Notification of M8 type Created
Presentation Title | Confidential | Document ID | Apr 9, 2023 111
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type
Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Screen of Measuring reading entry list: Create Appears
Enter entry list name & Description
Enter measuring point numbers As selected from drop down list
All details of Measuring points Appears in list
A Massage “ measurement reading entry list xxx saved.
Go to T. Code – IK31 - Measuring reading entry list: Create
Creation of Entry List
Click on Enter Button
Click on Enter Button
Now Click on Save Button
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 112
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITIONBASE MAINT. PROCESS
• Creation of Measuring Point
• Selection of Measuring Point
• Creation of Measuring
Document & Auto notification
• Creation of Entry List
• Measuring Document Thru
Entry list
• Selection of M8 type
Notification
• Creation of Corrective
Maintenance Order Thru
Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders
Navigate> SAP Screen
Enter Entry list number
Collective entry of MeasDocuments: overview screen Appears
Enter measuring Reading in relevant measuring point field
Go to T. Code – IK34 – Collective entry of MeasDocuments: Initial screen
Creation of Measuring Document Thru Entry list
Click on Enter Button
Click on Enter Button
A Massage Appears In case Reading is Outside range &click again enter button. M8 Notification will generate
A massage appears as xx Measuring document Created
Presentation Title | Confidential | Document ID | Apr 9, 2023 113
5. REPAIR MAINTENANCE PROCESS
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF REPAIR MAINTENANCE PROCESS
• Creation of M6-Notification
• Selection of M6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
Presentation Title | Confidential | Document ID | Apr 9, 2023 114
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M 6-Notification
• Selection of M 6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
Enter Notification Type
Do not Enter Notification Number
Go to T. Code – IW21Create Notification
Enter Notification Description
Enter Equipment / FL / Assembly (as required)
Enter Reported By (Name)
Select from Drill Down
H/L TO N/F Types
System Generated
Enter Code of STD TEXT Attached
Select from Drill Down as per requirement
Notification Tab Screen Appears
Manual Process
Click Enter Button
Creation of M6 Notification
Presentation Title | Confidential | Document ID | Apr 9, 2023 115
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M2-Notification
• Selection of M2-Notification
• Creation of PM02-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
• Why-Why Analysis
Go To Location Data Tab
Save the Notification
Write Details of Job in Long Text
Main Work center/ Planner Group etc Defaulted & can be Changed If Required
All information Defaulted from equipment master
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 116
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M6-Notification
• Selection of M6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
Flag check box Outstanding (as reqd)
Enter Notification Date
Go to T. Code – IW28 Selection of Notification
Select Notification & Create PM09 Type Order
Click Create button
of Order Tab
Selection of M6 Notification
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 117
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M6-Notification
• Selection of M6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
Select Relevant Work Center (Type 0001)
Enter Number of Hours
Select from Drill Down
Select Relevant Maintenance Activity Type( Always RVN)
Select from Drill Down
Other Field automatically Populated.
Go to Operation TAB
Navigate> SAP Screen
Select Relevant Work Center for Operator & Enter Number of Hours
Go to Component TAB & Attach Required Material
Create PM09 Type Order
Presentation Title | Confidential | Document ID | Apr 9, 2023 118
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M6-Notification
• Selection of M6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
GO to IW38 & Search PM09 Type Order
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 119
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M6-Notification
• Selection of M6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
Release Order & Issue Required Material.
Carry out Repair Work As per Request
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 120
5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of M6-Notification
• Selection of M6-Notification
• Creation of PM09-Order
• Selection of Order
• Execution of Orders
• Confirmation of Orders
• Technical Completion of Orders
• Execution & Completion of
Notification
Further process of order will remain same as explained in process “1. Preventive Maintenance”
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 121
6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC PROCESSES
1. Preventive Maintenance
2. Break down Maintenance
3. Shut down Maintenance
4. Condition base Maintenance
5. Work shop Repair
6. External Repair/Services
7. Calibration
BASIC STEPS OF EXTERNAL REPAIRMAINTENANCE PROCESS
• Creation of PM09 Type Order
• Selection PMEX Activity type
• Creation of Purchase
Requisition
• Creation Of Purchase Order
• Confirmation of External
Service Entry Sheet
• Technical Completion of Orders
Presentation Title | Confidential | Document ID | Apr 9, 2023 122
6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF EXTERNAL REPAIR PROCESSES
• Creation of PM09 Type Order
• Selection PMEX Activity type
• Creation of Purchase Requisition
Creation of Purchase Order
• Confirmation of External Service Entry Sheet
• Technical Completion of Orders
Select Relevant Type Maintenance Activity (Always RVN, RWN)
Select from Drill Down
Select Control Key As PMEX
Go to Operation TAB
Click External Service Button
Creation of PM09 Type Repair Order
Enter Operation & Select It
POP Screen Will Appear Enter Material Group S 524,Purchase Group, Tracking Number
Enter & GO to External Processing operation Screen
Select from Drill Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 123
6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of PM09 Type Order• Selection PMEX Activity type• Creation of Purchase
Requisition• Creation of Purchase Order• Confirmation of External Service
Entry Sheet• Technical Completion of Orders
Write Short Text of External Service , Approximate Cost of Repair, Quantity & Unit
Enter Cost Element & click
Pop Screen of Purchase request Will Appear Enter Department (i.e Main Planner group)
Go back to Order main screen Release it & Save Order
Go to Change Mode of Order & select TAB Actual Data You will get PR number
Write Desired Vendor Code
Select from Drill Down
Select from Drill Down
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 124
6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of PM09 Type Order Selection PMEX Activity type• Creation of Purchase
Requisition• Creation of Purchase Order• Confirmation of External
Service Entry Sheet• Technical Completion of
Orders
GO TO Customer TAB & Enter all Required Deatils
Go To Change Mode of PR (ME52N)
GO To Document Overview & Select Relevant PR
Save PR
Navigate> SAP Screen
Presentation Title | Confidential | Document ID | Apr 9, 2023 125
6. EXTERNAL REPAIR MAINTENANCE PROCESS
MM Will Prepare Purchase Order on PR
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of PM09 Type Order
• Selection PMEX Activity type
• Creation of Purchase Requisition
• Creation of Purchase Order
• Confirmation of External Service Entry Sheet
• Technical Completion of Orders
Presentation Title | Confidential | Document ID | Apr 9, 2023 126
6. EXTERNAL REPAIR MAINTENANCE PROCESS
MM Will Prepare Service Entry Sheet You will Accept Service Entry Sheet
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of PM09 Type Order
• Selection PMEX Activity type
• Creation of Purchase Requisition
• Creation of Purchase Order
• Confirmation of External Service Entry Sheet
• Technical Completion of Orders
Presentation Title | Confidential | Document ID | Apr 9, 2023 127
6. EXTERNAL REPAIR MAINTENANCE PROCESS
This Type of Order to be TECO only When FINAL Service Sheet Made.
BASIC STEPS OF MAINTENANCE PROCESSES
• Creation of PM09 Type Order
• Selection PMEX Activity type
• Creation of Purchase Requisition
• Creation of Purchase Order
• Confirmation of External Service Entry Sheet
• Technical Completion of Orders
Save
Presentation Title | Confidential | Document ID | Apr 9, 2023 128
III. MANAGING REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 129
STANDARD REPORTS
1. Object Class Statistics [MCI1]
Object breakdown analysis in terms of Maintenance cost
Standard drill down (Key Figure)
Assembly Construction yearManufacturer Material Object class
Month
Presentation Title | Confidential | Document ID | Apr 9, 2023 130
2. Manufacturer Analysis [MCI2]
Object breakdown analysis in terms of Maintenance costManufacturer wise.
Standard drill down (Key Figure) Assembly Construction yearManufacturer Material Object class Month
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 131
3. Location Analysis [MCI3]
Object breakdown analysis in terms of Maintenance cost Location wise
Standard drill down (Key Figure) AssemblyEquipmentFunctional LocationLocationMaintenance plantPlanner groupPlanning plantPlant sectionMonth
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 132
4. Planner Group Analysis [MCI4] Object breakdown analysis in terms of Maintenance cost
Planner Group wise
Standard drill down (Key Figure) AssemblyEquipmentFunctional LocationLocationMaintenance plantPlanner groupPlanning plantPlant sectionMonth
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 133
5. Single Object - Damage Analysis [MCI5]
Object Damage analysis in terms of Damage & Causes, Notification Type wise
Standard drill down (Key Figure)Activity codeCause of damageCdGrp: damage causeCode group: activityCode group: damageDamageEquipmentFunctional LocationNotification typeMonth
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 134
6. Object Statistics [MCI6]
This report provide the detail about the object statistics ( like how many Equipment installed on a Function Location)
Standard drill down (Key Figure)
Object classManufacturer Material Construction yearMonth
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 135
7. Breakdown Analysis [MCI7]
This report provide the Breakdown Analysis information(No. of B/D, MTTR, MTBR etc.).
Standard drill down (Key Figure)
EquipmentFunctional LocationObject classMonth
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 136
8. Cost Analysis [MCI8]
This report provide the Breakdown Analysis information( No. of B/D, MTTR, MTBR etc.).
Standard drill down (Key Figure)
EquipmentFunctional LocationObject classMonth
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 137
9. MTTR/MTBR Equipment [MCJB]
This report provide :
MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR etc.).
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 138
10. MTTR/MTBR Functional Location [MCJC]
This report provide :
MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR etc.)
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)
STANDARD REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 139
6.2 LIST OF DEVELOPED REPORTS
Presentation Title | Confidential | Document ID | Apr 9, 2023 140
The following are the Reports that are being developed in SAP:
LIST OF DEVELOPED REPORTS:
S. No. PLANT REPORTS
1 List of Damage & Cause - Summary Report (Equipment wise)
2 Breakdown Matrix - Equipment ABC indicator & breakdown category wise
3 Work Center / Equipment wise Material Consumption
4 Equipment Schedule Maintenance Report
5 Breakdown why-why Analysis Report
6 PM order Skipped / Rescheduled Report
7 PM Order Slippage Summary Report ( Schedule Maintenance Slippage in Plant VC)
8 Preventive Maintenance Work Request Report
9 Motor Failure Report
10 Inspection Check List
Presentation Title | Confidential | Document ID | Apr 9, 2023 141
S. No. PLANT REPORTS
11 Maintenance Order / Operation Pending List
12 Section / Equipment Performance Report
13 Equipment Lubrication Consumption Report
14 Quarterly Lubrication Consumption Report
15 Purchase Request Tracking Report
16 Equipment Maintenance Cost Report
17 List of Service Entry Sheets
18 Work Center Wise Service Cost Report
19 Shutdown (consolidated) Planning Report (resources & cost)
LIST OF DEVELOPED REPORTS:
Presentation Title | Confidential | Document ID | Apr 9, 2023 142
S.No. MINES REPORTS
20 Tyre Life Summary Report
21 Equipment Position Wise Tyre Run Report
22 Tyre Maintenance Register
23 Oil Consumption Report
24 Oil, Filter & Lubricant Monitoring Report
25 Assembly Life Details
26 Sub assembly Performance Report
27 Breakdown Summary
LIST OF DEVELOPED REPORTS:
Presentation Title | Confidential | Document ID | Apr 9, 2023 143
Presentation Title | Confidential | Document ID | Apr 9, 2023 144
Select Equipment
Select Relevant Measuring Point Category
Flag for Measuring Point as a Counter
Write Measuring Position Description
Write Description of Measuring Point
Measuring Point Object
Attach Relevant CHARACTERISTICS
Crete Measuring Point- IK01
CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1
Select from Drop Down
Select from Drop Down
Select from Drop Down
Select From Drop Down ,Always use RUNNINGHOURS
Presentation Title | Confidential | Document ID | Apr 9, 2023 145
Enter Annual Estimate Reading
Press ICON For Save
Message : “Measuring Point ………. Created
Enter Counter Over Flow Reading
Press Enter ICON
CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2
Maximum Reading of Counter
It Will be drive Plan
THE END
Presentation Title | Confidential | Document ID | Apr 9, 2023 146
Select Equipment
Select Relevant Measuring Point Category
Flag for Measuring Point as a Counter
Write Measuring Position Description
Write Description of Measuring Point
Measuring Point Object
Attach Relevant CHARACTERISTICS
Crete Measuring Point- IK01
CREATION OF MESURING POINT (LUB/Diesel Consumption) Sheet 1/2
Select from Drop Down
Select from Drop Down
Always Select Category L- for Lubrication & F- Fuel Consumption
Select From Drop Down , ,Always LUB CONCOSUMPTION…..
Presentation Title | Confidential | Document ID | Apr 9, 2023 147
Enter Save ICON Button
Message : “ Measuring Point ……..Created
Don’t Enter Counter Over Flow Reading & Annual Estimate Reading
Press Enter ICON
CREATION OF MESURING POINT(LUB/Diesel Consumption) Sheet 2/2
Enter Save ICON Button
Message : “ Measuring Point ……..Created The END
Don’t Enter Counter Over Flow Reading & Annual Estimate Reading
Press ICON
Presentation Title | Confidential | Document ID | Apr 9, 2023 148
Select Equipment
Select Relevant Measuring Point Category
Press Icon
Write Measuring Position Description
Write Description of Measuring Point
Measuring Point Object
Attach Relevant CHARACTERISTICS
Crete Measuring Point- IK01
CREATION OF MESURING POINT Sheet 1/2
Select from Drop Down
Select from Drop Down
Select from Drop Down
Select From Drop Down
Presentation Title | Confidential | Document ID | Apr 9, 2023 149
Enter Save ICON Button
Message : “ Measuring Point ……..Created
Don’t Enter Counter Over Flow Reading & Annual Estimate Reading
Press Enter ICON
CREATION OF MESURING POINT Sheet 2/2
Enter Save ICON Button
Message : “ Measuring Point ……..Created THE END
Don’t Enter Counter Over Flow Reading & Annual Estimate Reading
Press ICON
Presentation Title | Confidential | Document ID | Apr 9, 2023 150
Enter ICON Button Next Screen will Appear for entering Reading
Enter Counter Reading or Difference of Counter
Select Desired Measuring Point
Creation of Measuring Document IK11
CREATION OF MESURING POINT DOCUMENT (IK11)
Press ICON Button For Save
Select from Drop Down
Counter should be GREATER than Previous Reading or Difference not more than 24 Hours
Message : “Measuring Document ……..Created.
THE END
Presentation Title | Confidential | Document ID | Apr 9, 2023 151
WITH
TIME BASED PACKAGE
Continued..MAINTENANCE ITEM
Presentation Title | Confidential | Document ID | Apr 9, 2023 152
Maintenance Strategy
Write Maintenance Item Description
Enter Equipment
Write ORDER Type
Maintenance Activity Type
Maintenance Plan Category
Attach Relevant Task List
Create Maintenance Item IP04
CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04
Select from Drop Down
This will be PM01 Always
Select from Drop Down (Use PVM Or AMC )
Select from Drop Down
Select from Drop Down, Use Always GILDAY & GILMON Only
Presentation Title | Confidential | Document ID | Apr 9, 2023 153
Flag General Task List
Press Icon , Screen will appear with List of Task Lists
Select Appropriate Task List
Press Icon Enter
Press Icon for Save
Task List Display Screen will Appear on Screen
You will get Message : Maintenance Item ( System Generated Number) Created. THE END
For Selection of Task List Use Icon
CREATEING MAINTENANCE ITEM (TIME BASE) Sheet -2/2
Presentation Title | Confidential | Document ID | Apr 9, 2023 154
WITH
PERFORMANCE BASED PACKAGE
MAINTENANCE ITEM
Presentation Title | Confidential | Document ID | Apr 9, 2023 155
Maintenance Strategy
Write Maintenance Item Description
Enter Equipment
Write ORDER Type
Maintenance Activity Type
Maintenance Plan Category
Attach Relevant Task List
Create Maintenance Item IP04
CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2
Select from Drop Down
This will be PM01 Always
Select from Drop Down
Select from Drop Down
ALWAYS Use PERFHR –For Plant,TPP,DG Equipment & MINHR – For Mines Equipment
Presentation Title | Confidential | Document ID | Apr 9, 2023 156
Flag General Task List
Press Button , Screen will appear with Task List
Select Appropriate Task List
Press Icon
Press Icon for Save
Task List Display Screen will Appear on Screen
You will get Message : Maintenance Item ( System Generated Number) Created THE END
For Selection of Task List Use Button
CREATE MAINTENANCE ITEM (PERFORMANCE BASE )Sheet -2/2
Presentation Title | Confidential | Document ID | Apr 9, 2023 157
Creation of Maintenance Item-[IP04]
NAVIGATE > SAP SCREEN
Presentation Title | Confidential | Document ID | Apr 9, 2023 158
Maintenance Category
Maintenance Strategy
Press Icon
Write Maintenance Plan Short Description
Go to TAB For Assigning Maintenance Item
Maintenance Plan Number is System Generated Number
POP Screen will appear Message : Possible Deletion of Data Entered When Selecting
Create Maintenance Plan (IP01)
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3 IP01
Select from Drop Down ,Always Use GILDAY & GILMON
Presentation Title | Confidential | Document ID | Apr 9, 2023 159
Main Planner Group ,Main Work Center & other field automatically Populated
Main Planner Group ,Main Work Center & other field automatically Populated from Equipment Master
Press Icon
Go to TAB “Maintenance Plan Scheduling Parameter
Write Scheduling Period :365 Days
Main Planner Group ,Main Work Center & other field automatically Populated from Equipment Master
Flag Fro Completion Requirement
Display Maintenance Item :Selection Criteria Screen Will Appear ,Write Equipment Number & Press Icon
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 2/3
Presentation Title | Confidential | Document ID | Apr 9, 2023 160
Select Radio Button “NO”
Press Icon
Message will Appear on Screen :” Maintenance Plan ……….Created
The End
Pop Screen Will Appear For START DATE
Press Icon For Save
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 3/3
Presentation Title | Confidential | Document ID | Apr 9, 2023 161
Maintenance Category
Maintenance Strategy
Press Icon
Write Maintenance Plan Short Description & Enter Counter
Go to TAB For Assigning Maintenance Item
Maintenance Plan Number is System Generated Number
POP Screen will appear Message : Possible Deletion of Data Entered When Selecting
Create Maintenance Plan (IP01)
CREATION OF MAINTENANCE PLAN (PERFORMANCE BASE) Sheet 1/3
Select from Drop Down ,Always Select PERFHR –For Plant, DG, TPP & MINHR – For Mines
Presentation Title | Confidential | Document ID | Apr 9, 2023 162
Main Planner Group ,Main Work Center & other field automatically Populated
Main Planner Group ,Main Work Center & other field automatically Populated from Equipment Master
Press Icon
Go to TAB “Maintenance Plan Scheduling Parameter
Write Scheduling Period :365 Days
Main Planner Group ,Main Work Center & other field automatically Populated from Equipment Master
Flag For Completion Requirement
Display Maintenance Item :Selection Criteria Screen Will Appear ,Write Equipment Number & Press Icon
CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 2/3
Presentation Title | Confidential | Document ID | Apr 9, 2023 163
Select Radio Button “NO”
Press Icon
Message will Appear on Screen :” Maintenance Plan ……….Created
The End
Pop Screen Will Appear For START Counter Reading
Press Icon For Save
CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 3/3