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SAP PM USER TRAINING.pps
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PM MODULE FOR EBG -POWAI PLANT
TEAM LEADER : J S PATIL
TEAM MEMBERS : M M KUNTE SBU 2
: K A SARPOTDAR SBU 1 / SBU C
: T M RAJAGOPALAN SBU 3
: RAVI MORE PTL
TEAM STARTED WORKING FROM01/12/2000
WILL ‘GO LIVE’ IN 1ST WEEK OF APRIL 2001
PMPMPlant MaintenancePlant Maintenance
FIFIFinancialFinancial
AccountingAccounting
COCOControllingControlling
AMAMFixed AssetsFixed Assets
Mgmt.Mgmt.
PSPSProjectProjectSystemSystem
WFWFWorkflowWorkflow
MMMMMaterialsMaterials
Mgmt.Mgmt.PPPP
ProductionProductionPlanningPlanning
HRHRHumanHuman
ResourcesResources
SAP Plant Maintenance
SDSDSales &Sales &
DistributionDistribution
QMQMQualityQuality
ManagementManagement
Major sub-functions: Equipment and spares tracking Maintenance work management Preventive maintenance planning Maintenance information analysis (PM-IS) Measurements
SAP Plant Maintenance
Equipment and spares tracking Functional Location (P&ID) data Equipment data Bills of Material Permits Equipment Tasklists (Standard jobs) Functional/Location Tasklists General Tasklists
SAP Plant Maintenance
Contents of a Functional Location
Functional locationmaster record
Location data
PM data
Multilingual texts
Equipment usage
Classification
Documents
Contents of an Equipment Master Record
Equipment master record
General data
Location data
PM data
Multilingual texts
Internal note
Equipment usage
Classification
Documents
Maintenance Work Management creation of maintenance orders planning scheduling release confirmation settlement completion
SAP Plant Maintenance
Process Flow in PM
PM OrganizationPM Organization
PM ObjectsPM Objects
PlantsPM PlannerWork Centers(Workshops)Capacities
PlantsPM PlannerWork Centers(Workshops)Capacities
FunctionalLocations
Equipment
Assemblies
FunctionalLocations
Equipment
Assemblies
Direct ordercreation
Direct ordercreation
CompletionInformationCompletionInformation
ResourcesMaterial Internal External Services Services
PM HistoryDowntimes
Costs ....
PM OrdersPM Orders
PM Reqts./Notifications(Malfunction
reports)
PM Reqts./Notifications(Malfunction
reports)
PM Planning (Maintenance and
inspection releases)
PM Planning (Maintenance and
inspection releases)
Types of Maintenance Orders Preventive maintenance orders released by PM
schedules at due dates Planned orders arising from maintenance
notifications (malfunctions and work requests) Unplanned orders created if immediate action is
required Standing (blanket) work orders
SAP Plant Maintenance
Basic Steps in Maintenance Processing
Malfunction, errorRequestActivity
Malfunction, errorRequestActivity
PM Notificationwhatwhenwheretechn. information breakdown
Creating the orderPlanning the task
whowhen, for how longwhat stepsaccount assignment resources
Executionmaterial issueprocuring PRTswork steps
Techn. informationbreakdowncausesobjects affectedactivities
PM History
Completion
Requesting amaintenance
Task
1111
Order
Completionconfirmation
Completion
22223333 4444
5555
66667777
8888
Plant PM Planning PM Workshop
Preventive Maintenance Planning Time based maintenance strategies Performance based strategies Counter based strategies Maintenance Tasklists (Standard jobs) Maintenance Plans Maintenance Order Scheduling
SAP Plant Maintenance
Maintenance Task List Structure
Strategy, maintenance planning group, work center, equipment
Allocation of maintenance packages
Work center, description, time,control key, external processingdata, maintenance packages
Task list header
Operation
Maintenancepackages
Operation, time, work center, description, control keySub-operation
Quantity, BOM item, item category, quantity unit
Quantity, category
Material
Maintenanceresources
Maintenance OrderMaintenance OrderMaintenance PlanMaintenance Plan
MAINTENANCE STRATEGY
MAINTENANCE STRATEGY
MAINTENANCE PACKAGES:
-Time based-Performance based
- Counter based
MAINTENANCE PACKAGES:
-Time based-Performance based
- Counter based
SCHEDULED CALLS
SCHEDULED CALLS
MAINTENANCE ORDERS
MAINTENANCE ORDERS
MAINTENANCE ITEMS
MAINTENANCE ITEMS
-FUNCT LOCATIONS -EQUIPMENT -ASSEMBLIES
-FUNCT LOCATIONS -EQUIPMENT -ASSEMBLIES
ACTIVITIES:ACTIVITIES:
-Equipment Tasklists-Function Loc. Tasklists-General Tasklists
-Equipment Tasklists-Function Loc. Tasklists-General Tasklists
Maintenance Strategy
Maintenance Strategy
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Elements in Maintenance Planning
Maintenance information analysis Equipment breakdown Maintenance cost Like equipment analysis MTBF
SAP Plant Maintenance
Provides up to date cost figures for better maintenance decision making
Realtime information flows between PM and other systems
No software interfaces between plant maintenance (PM) system and other systems such as human resources, purchasing, payables, and payroll etc.
Eliminates the need to pull data from difference systems for reporting purposes
Lower software maintenance cost Lower software implementation cost
SAP Plant Maintenance - Benefits
Maintenance orders detailed description technical objects operations and sub-operations internal resources material list external resources schedule dates order header
SAP Plant Maintenance
for requesting a maintenance activity/task
for describing a maintenance activity that has alreadybeen performed - purely technical documentation
for describing the condition of a maintenance objectand the malfunction in particular
Definition of a Maintenance Notification
Malfunction report
Activity report
Maintenance request
Structure of a Maintenance Notification
date/time/reported by description PM object: functional location equipment assembly location data account assignment data breakdown/availability data
Activities
Maintenancetasks
damage locationdamagecause of damage
Notificationitems
Notification
activityperformed by
datestask description
PM Overview Diagram
Create Work Orders
Create Work Orders
NotificationsNotifications
PlannedWork Orders
PlannedWork Orders
Schedule WO’sSchedule WO’s
Parts/SuppliesParts/Supplies
Labor Labor
Preventive/PredictiveMaint. WO’sPreventive/PredictiveMaint. WO’s
Master Data Master Data
Close and Settle WOClose and Settle WO
ReportingReporting
Special ToolsSpecial Tools
Pre-defined work stepsPre-defined work steps
EmergenciesEmergencies
External ServicesExternal Services Material
RequisitionsMaterialRequisitions
ShopPapersShopPapers
Maintenance OrdersMaintenance Orders
NotificationsNotificationsVendorVendor
LocationsLocations
CostCost
SuppliesSupplies
PartsParts
PeoplePeople
PlantsPlants
Special ToolsSpecial Tools
Repair StepsRepair Steps
EquipmentEquipment
FactoryCalendarFactoryCalendar
PM Master Data
Planned Maintenance Order
Planned Maintenance Order
NotificationsNotifications
Emergency DemandEmergency Demand
MaterialAvailabilityMaterialAvailability
Stock ReservationsStock Reservations
Purchase RequisitionsPurchase Requisitions
Create Maint. OrdersCreate Maint. Orders
SafetyConsiderationsSafetyConsiderations
Capacity Demand(Labor)
Capacity Demand(Labor)
Special ToolsSpecial Tools
Special InstructionsSpecial Instructions
Delivery Schedule of Material/ServicesDelivery Schedule of Material/Services
Release the Maint. OrderRelease the Maint. Order
Schedule theMaint. Order1. Manual2. Automatic
Schedule theMaint. Order1. Manual2. Automatic
Material ReservationsMaterial Reservations
Requisitionto Purch. OrderRequisitionto Purch. Order
PP/ PMPP/ PM
Planning & Scheduling
OrderOrder
ProjectProject
AssetAsset
Completion confirmationCompletion confirmation
Invoice receiptInvoice receipt
Goods receiptGoods receiptPurchase ordersPurchase orders
Material issueMaterial issue
Externalprocessing
Externalprocessing
CostsCosts
Task listTask list
BOMBOMMaterialsMaterials
Maintenance Order Functions
Capacity planningCapacity planning
OperationsOperations
Work centersWork centers
Object listObject list
ObjectsObjects
Shop papersShop papers
Cost centerCost center
Planning
Execution
Settlement