SAP R3 Plant Maintenance

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



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



Different (Major) MaintenanceTypes

System generated Work Orders

Time dependent

Manual Intervention

Notifications or

Directly created Work Orders



SAPR/3Plant MaintenancAgenda

Introduction



Manual Intervention

History/Analysis



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



Reducesrecordingandmanagement effort

Simplifiesprocessing

Enablesbetterplanningandevaluation

Structuring



Structuring of Data

Functional Location

Structure Indicator

EquipmentObject Link

Material Master

Equipment Bill of Materials

Work Center

Maintenance Task List


Maintenance Item

Maintenance Plan

Notifications

PM order



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




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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



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


Work Center



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:


Equipment

1.Display: Equipment PT316

2.Create: Equipment TD100

3.Exercise(3): Equipment


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Structuring of Data

Functional Location

Structure Indicator


Material Master


Work Center



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:


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


Work Center



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


Work Center



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

Assembly

Spare Spare

Spare Assembly

Assembly

Spare Spare

Spare

level 1

level 2

level 0

Equipment

Assembly

Spares


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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:


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


Work Center



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


Material Master

Equipment Bill of Material

WorkCenter

MaintenanceTaskList

MaintenanceStrategy

MaintenanceItem

MaintenancePlan

Notifications

PMorder


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SAPR/3Plant Maintenanc

Agenda

Introduction



Manual Intervention

History/Analysis

Structuring of Data


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Structuring of Data

Functional Location

Structure Indicator

Equipment

Object Link

Material Master


Work Center



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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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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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


Work Center



Maintenance Item

Maintenance Plan

Notifications

PM order


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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


Material Master


Work Center



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:


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


Material Master


Work Center



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

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:


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


Material Master


WorkCenter

MaintenanceTaskList

MaintenanceStrategy

MaintenanceItem

MaintenancePlan

Notifications

PMorder


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SAPR/3Plant Maintenanc

Agenda

Introduction



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


Material Master


Work Center



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


Material Master


Work Center



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


Material Master


WorkCenter

MaintenanceTaskList

MaintenanceStrategy

MaintenanceItem

MaintenancePlan

Notifications

PMorder


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SAPR/3Plant Maintenan

Agenda

Introduction



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


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Plant MaintenanceProcess

Summarized

Youshouldbeableto

CreateaFunctional location(structure)

Createandinstall anequipment

CreateamaintenanceplanCreatenotifications

PMorderhandling

Exercise15 Plant MaintenanceProcess

Documents

SAP R3 Plant Maintenance