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7/28/2019 SAP R3 Plant Maintenance
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Plant Maintenance
Thegoal ofthissessionistogiveyouan introductiont
anda basic understandingof:
SAPPMphilosophy
SAPPMterminology
SAPPMscreens
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SAPR/3Plant Maintenance
Agenda
Introduction
StructuresandMasterData
SystemgeneratedMaintenance
Manual Intervention
History/Analysis
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Solutionsformanagement andmaintenanceof technica
systems
Maintenanceincorporates:Inspection: determinetheactual condition
Maintenance: maintaintheideal condition
Repair: restoretheideal condition
Constructionandmodification
SAPPlant Maintenance
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Management of operational systemsandtechnical
resources
RegularactivitiesscheduledviaMaintenanceplansMalfunctionsenteredasnotifications&passedtoplanni
MaintenanceOrdersforworkrequired
typeof activity, tasksteps, &resources
CompletedOrders=taskrelated, functionandobject
orientedhistory
Scopeof PMActivities
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Functionality
Can fulfil all day-to-day processing requirements of Plant
Maintenance
Experience and suggestions of varied customers used in
development
Fully integrated with other modules
Materials Management
Purchasing
Inventory Management
Financial Accounting
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Functional Overview
Client / Server
ABAP/4
R/3
SD
MM
PP
QA
PM
HR IS
OC
PS
AM
CO
FIPlant Maintenance (PM)
- Technical Objects
- Work centers- Main. task lists
- Maintenance planning
- PM Processing
- Capacity planning
- Information system
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Different (Major) MaintenanceTypes
System generated Work Orders
Time dependent
Manual Intervention
Notifications or
Directly created Work Orders
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SAPR/3Plant MaintenancAgenda
Introduction
StructuresandMasterData
SystemgeneratedMaintenance
Manual Intervention
History/Analysis
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Plant Maintenance, a lot of terms
Function
alloc
ation
ObjectLink
MaterialMaster
BillofMaterials
Work Center
MaintenanceTaskList
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notification
PM Order
Equipment
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Reducesrecordingandmanagement effort
Simplifiesprocessing
Enablesbetterplanningandevaluation
Structuring
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Structuring of Data
Functional Location
Structure Indicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Functional: locationorprocessorientedusinghierarchi
Object related: descriptionof everypieceof equipment
Technical: allocateobjectstodifferent classes
Accounting: allocateobjectstocost centresorassets
Structuring
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Functional Location Structure
San Jose
Production
Test ... Process
LINE 1 LINE 2 LINE 3
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Functional LocationStructure
StructureIndicator: ABC1Edit Mask: XXXX-XXX-XX-XXX-XXX-XXX
Hier. Levels: 1 2 3 4 5 6
FUNCTIONALLOCATION DESCRIPTION
PL01 SanJose
PL01-PRD Production
PL01-PRD-PR Process
PL01-PRD-PR-LN1 Line1
PL01-PRD-PR-LN2 Line2
PL01-PRD-PR-LN3 Line3
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Functional Location
StructureIndicator
TodescribethenumberstructureofFunctional Locat
Todefinethehierarchylevels
Todescribeall similarfunctional locationsinth
Astricttopdowndefinition
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CreateFunctional Location
StructureIndicator
MenuPath:
Tools - Customizing - Configuration - Logistics - Plant
Maintenance - Master Data - Technical Objects - Functio
Location - StructIndicator
1.Display: PL01
2.Create: StructureIndicator, ABCX(AAA-XXXX-
3.Exercise(1): SeeParticipant handout (Struct. Indicat
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Functional Location Structure
PL01 San Jose
PL01-PRD Production
PL01-PRD-PR Process
PL01-PRD-PR-LN1 Line 1
PL01-PRD-PR-LN2 Line 2
PL01-PRD-PR-LN3 Line 3
San Jose
Production
Test...
Process
LINE 1 LINE 2 LINE 3
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CreateFunctional Location
Menupath:
Logistics - Plant Maintenance - Technical Objects -
Functional Location
1.Display: Functional LocationPL01
2.Create: Functional Location, usageof TRW(2levels)
3.Exercise(2):Functional Location
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Equipment
Definition:An individual, physical object
which is to be maintainedindependently
Equipment
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Equipment data
General data
Locationdata
PMdataSalesanddistributiondata
Multi lingual texts
Linktodocuments( drawings, ref. manualset
Linktofunctional location
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CreateEquipment
MenuPath:
Logistics - Plant Maintenance - Technical Objects -
Equipment
1.Display: Equipment PT316
2.Create: Equipment TD100
3.Exercise(3): Equipment
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Structuring of Data
Functional Location
Structure Indicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Object Link
Definition
arelationshipbetween2technical systems(functional
locationorequipment) horizontally
Use
Tobeabletoanalysetheimpact onothersystemswhen
anotherhasmalfunctions/ plannedmaintenance
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Object Link, characteristics
Different types:
Host A Host B
Pump A Pump B
One-Way Link
Two-Way Link
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Object Link
Menupath:
Logistics - Plant Maintenance - Technical Objects -
Equipment OR Functional Location - Object Link
1.Display: Object Links#: 10000001
2.Create: Object Links: PT316and15-PU-15A
3.Exercise(4): Object Links
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Material Master views
Material
Master
record
Purchasing
Inventory
Engineering
Accounting
ForecastingSales
MRP
The Material Master Record is a central data object in the SAP system.
St t i f D t
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Equipment Bill of Material
Equipment
Spare Spare Spare
15-PU-15A
Definition:
a complete formally structured list representing all parts, material, documentsrequired to maintain an equipment
Equipment
Spares
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Equipment Bill of Materials
Equipment
Assembly
Spare Spare
Spare Assembly
Assembly
Spare Spare
Spare
level 1
level 2
level 0
Equipment
Assembly
Spares
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Equipment Bill of Materials
15-PU-15 A LUBRICATION PUMP
5014-0042 BEARINGS RHP.NH314
5014-0043 BEARINGS SKF.Q1314MA
5021-0031 BEARINGS RHP.N221 ECP
7501-0459 SEALS OIL 90 x 130 x 127501-0532 SEALS OIL 110 x 130 x 12
1700-0014 PUMP SHAFT 304L
1700-0015 PUMP IMPELLOR 304L
1700-0023 RINGS WEAR CASING POS NO 9-9/1
1700-0028 GASKET SETS
etc.
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CreateEquipment Bill of Materials
Menupath:
Logistics - Plant Maintenance - Technical Objects - BO
Equipment BOM
1.Display: Equip. BOMPT316or15-PU-15Al
2.Create: Equip. BOMTD100
3.Exercise(5):Equipment Bill 0f Materials
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Install Equipment
Menupath:
Logistics - Plant Maintenance - Technical Objects -
Functional Location
1.Display: Install Equipment PT316(SLK-CR300-A1)
2.Create: Install Equipment TD100onBRU-level
3.Exercise(6): Install Equipment
Structuring of Data
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
WkCt
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WorkCenters
Aworkcenterdefineswhereanoperationcanbeexecuted
(amachineoragroupof machines), orwhoistocarryout
anoperation( apersonoragroupof people).
Intheworkcenteryoucancalculatecosts, capacitiesand
datesfortheoperations.
Workcenterscanbestructuredhierarchically. Inthiswayrequiredandavailablecapacitycanbecumulated
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Work center, characteristics
Work center
Schedulingdata and
availablecapacity
Task List
Lead time
Scheduling
Capacity planning
0
20
40
60
80
100
Costing
2724,00
1200,00124,00
4048,00
Costing
data
Default
values
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CreateWorkCenter
Menupath:
Logistics - Plant Maintenance - Work Centers - Work Cet
1.Display: WorkCenter, PMWC100
2.Create: WorkCenter, PMWC500
3.Exercise7:WorkCenter
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Structuringof Data
Functional Location
StructureIndicator
EquipmentObject Link
Material Master
Equipment Bill of Material
WorkCenter
MaintenanceTaskList
MaintenanceStrategy
MaintenanceItem
MaintenancePlan
Notifications
PMorder
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SAPR/3Plant Maintenanc
Agenda
Introduction
StructuresandMasterData
SystemgeneratedMaintenance
Manual Intervention
History/Analysis
Structuring of Data
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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i
hatr
histt
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Task List
Work to be done Resource
Disconnect Motor Electrical Department
Make a scaffold External contract
Remove insulation External contract
Replace A with B Mechanical WorkshopReplace insulation External contract
Connect Motor Electrical Department
Test NA Mechanical Dept.
M i t T k Li t
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Maintenance Task List
Definition:
a sequence of individual maintenance activities which must
be performed in order to fulfill a certain maintenance
requirement
Characteristics:can be defined for a particular equipment or as a general list
multiple alternatives per task list
sequence of operations per task list
only one capacity requirement per operation
required material per operation
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Maintenance Task List
Material Allocation
Equipment
operation 2 operation 3 operation 4operation 1
2 x Item B 1 x Item C1 x Item A
Task List
Equipment
Bill of Materials
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CreateMaintenance
TaskList
Menupath:
Logistics - Plant Maintenance - Maintenance Task Lists -
Maintenance Task Lists - Equipment task lists
1.Display: MaintenanceTaskLists, PT316
2.Create: MaintenanceTaskLists, TD100
3.Exercise(8): MaintenanceTaskLists
Structuring of Data
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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Maintenance Strategy
15
When are jobs to be performed ?
Yearly ?
Monthly ?
Weekly ?
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MaintenanceStrategy
Definition:
ascheduleof plannedmaintenanceactivitieswhichshould
takeplaceat predefinedintervals
Characteristics:
Independent of anyequipment orfunctional location
schedulebyeithercalendarorkey-date
rulesforearlyandlateconfirmation
variablenumberof maintenancepackages
packagehasdescription, frequencyandpriority
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MaintenanceStrategy
Package1:
weeklyroutinecheck
Package2:
monthlypressurecheck
Package3:
yearlyoverhaul
Maintenanceof pressurizedcontainerExample
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Menupath:
Logistics - Plant Maintenance - Maintenance planning -
Maintenance strategy
1.Display: MaintenanceStrategies, ST001
2.Exercise(9): MaintenanceStrategies
DisplayMaintenanceStrategy
Structuring of Data
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Structuring of Data
Functional Location
Structure Indicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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How to combine
Maintenance task listWhat work has to be done ?
Who is to do the work ?
Maintenance strategyWhen are jobs to be performed ?
Functional location
Equipment
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Amaintenanceitemdescribestheactivitiestobecarri
outonanobjectandtheirfrequency
Usageof aMaintenanceite
Note:
AMaintenanceitemISNOTanEquipment (e.g. inst
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Maintenance Item
Maintenance Item
Strategy
Primary Object
Location/accountassignment
Description
Object List
Equipment #
Funct. locations
Task List
Operations
The maintenance item describes the type of maintenance or inspectionactivity to be carried out on a object (using short and long texts).
Mit it
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Maintenanceitem
DueDates
Maintenancestrategy
Maintenancepackage
Activities
Tasklist
withoperations
MaintenanceItemMaintenanceobjectswith
taskstobecarriedout
MaintenancePlanDates
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CreateMaintenanceitem
Menupath:
Logistics - Plant Maintenance - Maintenance planning -
Maintenance Items
1.Display: MaintenanceItems, SLK-MP-03
2.Create: MaintenanceItems, TD100(MI-SLK-TD01
3.Exercise(10):MaintenanceItems
Str ct ring of Data
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Structuring of Data
Functional Location
Structure Indicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
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Maintenance Plan
System generates
Work Orders based
on planned dates
Combination of
MaintenanceStrategies and
Task Lists
Due Dates
Maintenance strategy
Maintenance package
Activities
Task list
with operations
Maintenance Item
Maintenance objects with
tasks to be carried out
Maintenance Plan
Dates
M i Pl
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Maintenance Plan
Describes dates and scope of the maintenance activities to
be performed
Characteristics:
combination of maintenance items
all items selected must have the same strategy
includes the cycle start date
basis for scheduling maintenance orders
MaintenancePlan
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Scheduling
Thefollowingdataisusedtoautomaticallyschedule
maintenanceorders:
Thestart dateandlast completionconfirmationfro
theplan
openingperiod(%of cycletime)
shift factors(early / lateconfirmation) (Slide)
tolerances(basedonsmallest interval)
call interval (actual lengthof schedulingperiod)
thecyclesandthetasklist fromtheitem
thepackagesfromthestrategy
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Maintenanceplan,shiftfactorsexample
Planned ConfirmedNextdate Shift
date on planned fact
01.08.99 16.08.99 01.09.990
16.09.99 100
08.09.99 50
Maintenance plan call status
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Maintenance plan, call status
When a maintenanceplan is scheduled all
orders get the status ON
HOLD
Other possible
stati are:
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Elements in Maintenance Planning
Maintenance Strategy
Maintenance
packages:
time-dependentactivity-based
MaintenanceStrategy
Maintenance Plan
MaintenanceSchedule
Maintenance
Item
Maintenance Call
Scheduleforecast
Maintenance
Orders
Objects
Funct. locations
Equipments
Task lists
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CreateMaintenanceplan
Menupath:
Logistics - Plant Maintenance - Maintenance planning -
Maintenance Plans
1.Display: MaintenancePlans, MP-SLK-DEMO
2.Create: MaintenancePlans, useMI-SLK-TD01
3.Exercise(11):MaintenancePlans
StructuringofData
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Structuringof Data
Functional Location
StructureIndicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
WorkCenter
MaintenanceTaskList
MaintenanceStrategy
MaintenanceItem
MaintenancePlan
Notifications
PMorder
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SAPR/3Plant Maintenanc
Agenda
Introduction
StructuresandMasterData
SystemgeneratedMaintenance
Manual Intervention
History/Analysis
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Maintenance Order
PM Orders
PM planning PM NotificationsDirect order
creation
Structuring of Data
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Structuring of Data
Functional Location
Structure Indicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
N tifi ti
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Notifications
Result from unplanned, reportedexceptions
Allow for planning of resources
Not used in critical situations, whenOrder is entered directly
Definition:A document which holds all data which is needed to trigger an unplannedmaintenance activity or data on an activity performed already
Notification Types
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Notification Types
Malfunction report:Describes a malfunction, which normally affects the availability ofand object and leads to a maintenance order.
Activity report:
Describes a maintenance activity which has already been carriedout, not necessarily due to malfunction. For documentationpurposes.
Maintenance request:
A request for the maintenance department to carry out an activity
not based on malfunction.
Notification Structure
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Notification Structure
NOTIFICATION HEADER
NOTIFICATION TASKS
NOTIFICATION ITEMS
ACTIVITIES
Date/Time/Reported by
Description
PM Object: Functional
location
Equipment
Assembly
Damage location
Damage
Cause of Damage
Activity
Execution factors
Dates
Task Description
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Create Notification
Menu path:
Logist ic s - Plant Maintenance - PM Processin g - Noti f icat ion s
1. Display: Maintenance Notifications, 10000040, PT316
2. Create: Maintenance Notifications, TD100
3. Exercise (12): Maintenance Notifications
Structuring of Data
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g
Functional Location
Structure Indicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order
M i t O d
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Maintenance Order
Definition:
A document used to:
plan the execution,monitor the progress of maintenance activities in
detail
to collect all costs accrued during execution.
PM Orders
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Maintenance Order Creation
Based on one or more existing notifications
Created automatically based on a maintenance plan
Entered manually
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PM Order Structure
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PM Order Structure
HEADER
LOCATION and
ACCOUNTING
OBJECT
SETTLEMENT
OPERATION
COMPONENT
number, description, date, type, priority
physical location, suggested account assignment
functional locations, equipment, assemblies, notifications
planned/actual costs, final account assignment
description of work to be done, scheduling data
materials needed for work
PMOrderIntegration
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OrderCostsmaintainedthroughout thecycle (Finance)
Reservationsforplannedmaterials(MM- inventory)
Requisitionsfornon-stockitemsorservices(MM-
purchasing)
PMOrderIntegration
Order Costing
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g
PM ORDER
Internal processingOp. 10 ME 3 hrs
Op. 20 EL 1 hr
External processing
Op. 30 EXT 1 hr
Stock material
2 pcs material ABC
Non-Stock material2 pcs material XYZ
COSTS
Internal
Processing 500
External
Processing 150
Stock
Material 300
Non-stock
Material 500--------
Total 1450
Maintenance Processing
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for Unplanned Tasks
PM NOTIFICATION
What
When
Where
---------------------------
Techncalinformation
Breakdown
Malfunction, errorrequest, activity
Create the orderPlanning the task
Who
When, for how long
What steps
Resources
Technical information
Breakdown
Causes
Objects affected
Activities
PM History
Execution
material issue
procuring PRTs
worksteps
Completion1
2
3
4
5
6
7
8
Requesting
a task
Releasing
the order
Maintenance Processing
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1. Reporting a malfunction or a defect in a system or part thereof (iedescribing the condition of the system
2. requesting a maintenance task
3. creating a maintenance order and planning the task
4. releasing the maintenance order
5. executing the order
6. completing the task and confirming completion of order
7. entering technical information such as findings, cause, downtime,
activities
8. completing the order and the notification, storing relevant data for
evaluations, and for planning future maintenance activities
g
for Unplanned Tasks
M i t O d St t
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Maintenance Order Status
CRTD : after creation
REL(R) : released (rejected) - papers can be printed, time recordedand material issued
PRC : pre-costed (standard costs have been calculated)
(P)CNF : (partly) confirmed - time used has been recorded
MSPT : missing parts
TECO : technical completion
C t M i t O d
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Create Maintenance Order
Menu path:
Logist ic s - Plant Maintenance - PM Process ing - Orders
1. Display: Maintenance Orders, 900098
2. Create: Maintenance Orders, with reference to 10000040
3. Exercise (13): Maintenance Orders
Structuringof Data
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Functional Location
StructureIndicator
EquipmentObject Link
Material Master
Equipment Bill of Materials
WorkCenter
MaintenanceTaskList
MaintenanceStrategy
MaintenanceItem
MaintenancePlan
Notifications
PMorder
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SAPR/3Plant Maintenan
Agenda
Introduction
StructuresandMasterData
SystemgeneratedMaintenance
Manual Intervention
History/Analysis
M i t Hi t
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Maintenance History
UsageHistory
OrderHistory
NotificationHistory
Masterrecords
EquipmentFunctional
Location
PM
Notification
PM Order
Costs
Materials
Operations
View Maintenance History
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View Maintenance Historyand analysis
Menu path:
Logist ics - Plant Maintenance - PM Process ing - History - Noti f icat ion L ist -
Display
Logist ics - Plant Maintenance - PM info rmation sys tem - Standard
Analyses - Manufactu rer - Display
Exercise (14): History and PM information system
PlantMaintenanceProcess
7/28/2019 SAP R3 Plant Maintenance
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Plant MaintenanceProcess
Summarized
Youshouldbeableto
CreateaFunctional location(structure)
Createandinstall anequipment
CreateamaintenanceplanCreatenotifications
PMorderhandling
Exercise15 Plant MaintenanceProcess