Team Training - SAP Plant Maintenance Overview

© 2006 IBM CorporationOctober 24, 2007

SAP Plant Maintenance

Purpose: to begin understanding of SAP Plant Maintenance module

© 2006 IBM CorporationVerizon Fleet Management – Planning Meeting October 24, 2006

Maintenance Management in SAP R/3

R/3R/3Client / ServerClient / Server

ABAP/4ABAP/4

FIFIFinancialFinancial

AccountingAccounting

COCOControllingControlling

AMAMFixed AssetsFixed Assets

Mgmt.Mgmt.

PSPSProjectProjectSystemSystem

WFWFWorkflowWorkflow

ISISIndustryIndustry

SolutionsSolutions

MMMMMaterialsMaterials

Mgmt.Mgmt.

HRHRHumanHuman

ResourcesResources

SDSDSales &Sales &

DistributionDistribution

PPPPProductionProductionPlanningPlanning

QMQMQualityQualityMgmt.Mgmt.

PMPMPlantPlant

MaintenanceMaintenance


Plant Maintenance Organizational Elements


Master Data

Work OrderManagement

SAP Plant Maintenance Organizational Elements

Prev Maintenance


Master Data

EquipmentMaster

Functional Location

Task List

Bill of Materials

Workcenter

Planner Group

Measurements

Classification



Master Data

EquipmentMaster

Functional Location

Task List

Bill of Materials

Workcenter

Classification


Notification

WorkOrder

Planning

Scheduling& Execution

MaterialAcquisition

ReportLabor

ReportHistory

Planner Group

Measurements



Master Data

EquipmentMaster

Functional Location

Task List

Bill of Materials

Workcenter

Classification


Notification

WorkOrder

Planning


ReportLabor

MaterialAcquisition

ReportHistory

Prev MaintenanceMaintenance

Plans andItems

Strategy

Scheduling

Planner Group

Measurements



Master Data


Prev Maintenance

EquipmentMaster

Functional Location

Task List

Bill of Materials

Workcenter

Planner Group

Classification

Notification

WorkOrder

Planning


ReportLabor

MaterialAcquisition

ReportHistory

MaintenancePlans and

ItemsStrategy

Scheduling

Measurements



PM/PS Business Process DiagramHigh Level Business Process

Operations - Overview of Work Order Management Business Processes using the SAP Plant Maintenance and Project Systems Modules



Ma

ster

Dat

aan

d P

reve

ntiv

eM

ain

tena

nce

Com

ple

tion

Sch

edu

le a

ndE

xecu

tion

Cap

ital P

roje

ctM

ate

rials

Ma

nag

em

en

tW

ork

Ord

er

Pla

nnin

gT

rigg

er

Need for Repair, NewEquipment, New

Construction, or Materialidentified

CapitalExpenditure?

Included incurrent Capital

Budget?

Request Approvalfor unbudgeted

CapitalExpenditure

No

Yes

Create Notification

Is repair orinstallation to be

charged to a workorder?

No

Yes

EquipmentPurchase

Only?Yes

CreatePurchase

Requisition

PreparePreliminary Design

PackageRoute for Approval Approved?

Cancel or Resubmit

CreatePurchase Order

Create Order

Plan Order(labor, material,

contractorservices)

Arematerials or

Contract Servicesrequired?

Release OrderOrder Approvedfor Execution?

YesCancel orResubmit

No

Materialin Stock?

Issue material to Work OrderYes

Receive Material

Order Pendingin Backlog

Yes

Schedule Work tobe Performed

Dispatch Work toCrew

Print Shop Papers

Necessarymaterials,

contractors, tools,etc available?

ServicesSend PO/release to Contractor

Materials

YesPerform Work

OrderReplenishment

Material

Report HistoryCodes

Report LaborHours

No

Record ContractorService Usage

Prepare ProjectDefinition andWBS Structure

Prepare Budgetand Spending Plan

No

Create/MaintainEquipment Master

Request NewMaster Datato be set up

or maintained

NoMD

MDCreate/Maintain

FunctionalLocation

Create/Maintain Maintenance Plan(inspection, preventive maintenance)

Create/MaintainTask Lists

Create/MaintainBill of Materials

MaintainMaster Data

INSPSchedule

Maintenance Plan

Automatic Creation ofInspection or Preventive

Maintenance Notifications

INSP

Complete/Close WBS

Project

Complete/Close Work

Order

Either

CapitalPurchase

Only?

No

As Required

Yes

No

No

Prepare DetailDesign Package

No

Issue material to Capital ProjectYes

for Services



Ma

ster

Dat

aan

d P

reve

ntiv

eM

ain

tena

nce

Com

ple

tion

Sch

edu

le a

ndE

xecu

tion

Cap

ital P

roje

ctM

ate

rials

Ma

nag

em

en

tW

ork

Ord

er

Pla

nnin

gT

rigg

er



CapitalExpenditure?


Budget?


CapitalExpenditure

No

Yes

Create Notification



No

Yes

EquipmentPurchase

Only?Yes

CreatePurchase

Requisition


PackageRoute for Approval Approved?

Cancel or Resubmit


Create Order


contractorservices)

Arematerials or


Release OrderOrder Approvedfor Execution?

YesCancel orResubmit

No

Materialin Stock?

Issue material to Work OrderYes

Receive Material


Yes



Print Shop Papers

Necessarymaterials,


ServicesSend PO/release to Contractor

Materials

YesPerform Work

OrderReplenishment

Material

Report HistoryCodes

Report LaborHours

No




No



or maintained

NoMD

MDCreate/Maintain

FunctionalLocation




MaintainMaster Data

INSPSchedule

Maintenance Plan



INSP

Complete/Close WBS

Project

Complete/Close Work

Order

Either

CapitalPurchase

Only?

No

As Required

Yes

No

No


No

Issue material to Capital ProjectYes

for Services

Repair



Ma

ster

Dat

aan

d P

reve

ntiv

eM

ain

tena

nce

Com

ple

tion

Sch

edu

le a

ndE

xecu

tion

Pla

nnin

gW

ork

Ord

er

Ma

teria

lsM

an

age

me

nt

Cap

ital P

roje

ctT

rigg

er

No

Yes

No

Yes

Yes

YesNo

Yes

Yes

Services

Materials

Yes

No

No

No

Either

No

As Required

No

No

Yes

for Services

Cancel orResubmit


CapitalExpenditure


Materialin Stock?

Create Order

Cancel or Resubmit



or maintained

Yes

Receive Material

MD




OrderReplenishment

Material

Issue material to Work Order


CapitalPurchase

Only?

Create/MaintainFunctionalLocation

Send PO/release to Contractor


Perform Work

Necessarymaterials,


Report LaborHours

INSP

MD


Complete/Close WBS

Project


Arematerials or


Release Order



EquipmentPurchase

Only?

INSP





contractorservices)

Order Approvedfor Execution?


Budget?


Report HistoryCodes

ScheduleMaintenance Plan

No

Route for Approval

CapitalExpenditure?


Package

MaintainMaster Data

Approved?

Create Notification




Complete/Close Work

Order

Issue material to Capital Project

CreatePurchase

Requisition

Print Shop Papers

Repair with Materials/Services



Ma

ster

Dat

aan

d P

reve

ntiv

eM

ain

tena

nce

Com

ple

tion

Sch

edu

le a

ndE

xecu

tion

Pla

nnin

gW

ork

Ord

er

Ma

teria

lsM

an

age

me

nt

Cap

ital P

roje

ctT

rigg

er

No

Yes

No

Yes

Yes

YesNo

Yes

Yes

Services

Materials

Yes

No

No

No

Either

No

As Required

No

No

Yes

for Services

Issue material to Capital Project

INSP

Materialin Stock?

Create Notification

Send PO/release to Contractor

OrderReplenishment

Material

Print Shop Papers

Route for Approval


MDYes

No


contractorservices)

Necessarymaterials,


MD

CapitalPurchase

Only?

Create Order

Cancel or Resubmit

Arematerials or


Receive Material

MaintainMaster Data


Budget?

Create/MaintainFunctionalLocation



EquipmentPurchase

Only?


CapitalExpenditure

Report HistoryCodes



ScheduleMaintenance Plan


Order Approvedfor Execution?


Complete/Close WBS

Project




Report LaborHours

CapitalExpenditure?

Approved?

CreatePurchase

Requisition



Perform Work

Issue material to Work Order



Package

Release OrderComplete/

Close WorkOrder

INSP






or maintained


Cancel orResubmit

Capital


Design Considerations for a Work Order Management System

Treatment and design of capital and expense work orders.

Conversion of history and the format will it be stored.

Set-up of Preventive Maintenance to auto-generate released work orders vs. having a planner review the orders prior to releasing the orders.

Use of detailed scheduling of work orders and individuals.

Skills tracking and how the information is used in planning work.

Collection of information surrounding breakdowns, reason codes, failure information, etc.

Culture changes necessary to move from a primarily manual work management tool to an automated system.

Design of the process by which work order planning, scheduling, releasing, and completing work orders will be handled.

Design of the master data (equipment and functional locations) so that the business goals can be achieved without hampering the daily operations.


PM and FICO Relationship


Relationship between Plant Maintenance and FI/CO

Cost Center“Producing”

ActivityTypes

Pay

roll

Ben

efit

sO

verh

ead

s, e

tc

• gl• Activity types• etc

• gl• $ per Hour

CostCenter

Hierarchy

FI/CO Plant Maintenance

WorkCenter

$ per Hour times Labor Hours

Work OrderValue Categories

Labor, Internal .......Group of gl’sLabor, External .......Group of gl’sMaterial, Internal ... Group of gl’sMaterial, External ... Group of gl’sMisc ................. Group of gl’s

$$

Materials

PurchaseOrders• gl – internal material

• gl – spare parts• gl – supplies• gl – services• gl …… etc

Inventory

MRP / Purchase

Order

$$

$$

Cost Center“Receiving”

InternalOrder

WBSProject

Other….

FI/CO

PS

• gl• Activity types• etc

Settlement

Functional Location

Equipment Master

History Codes

Fu

nctio

nal

Lo

catio

n S

tru

ctu

reC

lass

an

d C

ha

ract

eri

stic

sW

orkC

ente

rP

lan

ne

r G

rou

pC

ost

Cen

ter

(wh

o p

ays

fo

r R

epa

irs)

Cla

ss a

nd

Ch

ara

cte

rist

ics

Ma

nu

fact

ure

rM

od

el

Dam

age

Co

des

Obj

ect

Pa

rt C

od

es

Cau

se C

od

es

Act

ivity

Cod

es

$$

$$

$$

Documents

Team Training - SAP Plant Maintenance Overview