UM Preventive Maintenance

PREVENTIVE MAINTENANCE PROCESSSAP PM

Preventive Maintenance Process

OverviewPreventive Maintenance is used to avoid system breakdowns or the breakdown of other objects, which - in addition to the repair costs - often result in much higher costs subsequently owing to production breakdown.

There are many benefits in using preventive maintenance within your company. It is the generic term for inspections, preventive maintenance and planned repairs, for which the time and scope of the work can be planned in advance. You can use maintenance plans to describe dates and the extent of preventive and inspection maintenance tasks which can be planned for technical objects. You can ensure that your technical objects are always maintained on time and in this way, ensure that they function optimally.

Integration The Maintenance Planning component is integrated with the following components and sub-components of the SAP System: Plant Maintenance application component · Maintenance task lists · Maintenance orders · Maintenance notifications Materials Management application component · Service procurement · Service entry sheets Quality Management application component · Inspection characteristics · Inspection lots

Purpose Use this procedure to create Preventive Maintenance Plan 1. Single Cycle Plan 2. Strategy Plan 3. Multiple Counter plan

Trigger Perform this procedure when there is a need for scheduled maintenance for the technical objects.

Prerequisites Technical Object (Functional Location / Equipment) Maintenance Strategy (for Strategy Plan) Task list Order type / Notification type

Maintenance PlansMaintenance Plan describes the maintenance and inspection tasks to be performed at maintenance objects with the date and scope of the tasks.

CREATED BY: GAURAV SOLANKI DATE: 14.04.2014 P a g e | 2


Time -Based Maintenance PlanIn time based maintenance planning maintenance is performed in specific cycles , for example , every two month or every six month.

Maintenance Planning is done to describe the date and scope of corrective maintenance and inspection activities at technical objects. This ensure that the technical objects are maintained on time and thereby function optimally.

The maintenance planner also needs to identify the units for the maintenance plans time (weekly , monthly , yearly , etc) or performance (every 100 running hours , every 10000 shots etc). For performance based maintenance plans relevant measuring counter needs to be defined for the technical object and measurement readings need to be updated regularly.

Module: PM Title:Creation Of Single Cycle Maintenance PlanTransaction Code: Create:IP41Change:IP02Display:IP03

Menu Path: Logistics Plant Maintenance Preventive maintenance Maintenance Planning Maintenance Plans Create(IP41)

Double click to reach the following screen



Field name Required/Optional

User action and allowed values

Maintenance Plan Category

R Choose the Maintenance Category :“Maintenance Order”

Press the enter key to get the following screen

In the screen , enter the values in the following fields.





Description R Enter the Maintenance Plan descriptionCycle/Unit R The maintenance period and the unit of period should

be entered.Ex 2 Mon 30 days etc.Cycle Text O Enter proper text to describe the cycle duration.Offset /Unit O The time period by which the first scheduled call object

should be postponed Counter O If the maintenance activity is performance based ,

counter should be used.Example “Number of operations/hours a motor is run”etc.

Reference Object:Functional Location

O/R Reference object on which the maintenance activity should be carried out.

Equipment O/R Reference object on which the maintenance activity should be carried out.After selecting equipment press enter key so that system selects data from the master.

Planning Plant R Enter Planning Plant if you selected the equipment then system call default values from the master.

Main Work Center Enter the Main Work CenterOrder Type R Enter Maintenance Order type:-Ex PM02 on which the

maintenance call objects will be created.Task List O Assign a Task List either general equipment of

functional location task list.

Click on icon to reach the following screen.



In the screen , enter the value in the following fields:-



Call horizon O % of scheduling period that should be consider in planning.if nothing is mentioned 100% will be considered.

Scheduling Period O Planning period during which call objects will be created as per the cycle duration.

Start Of Cycle O Enter the date on which the planning cycle should start.

Click on to save the created single cycle plan

After enter all require values , click on to save the notification and following message will be given by the system.


Call Horizon- Here fill percentage when the call to be come for maintenance . Example:- If cycle=100 days , & call horizon=90% , means at 90th day we will receive the order , for planning the man & material required to complete the maintenance order.Scheduling Period -Now we will fill the maintenance plan scheduling parameters i.e the time for which we will schedule this plan.Example- If we take sch. Period 10 year then total 10 nos maintenance order will generate with yearly cycle


CREATE MAINTENANCE PLANS:-STRATEGY PLAN

Double click to reach the following screen

Module: PM Title:Maintaining of Master date-EquipmentTransaction Code: Create:IP42

Menu Path: Logistics Plant Maintenance Preventive maintenance Maintenance Planning Maintenance Plans Create(IP42)-Strategy Plan

Field name Required/Optional User action and allowed values

Maintenance Plan Category

R Choose the Maintenance Category :“Maintenance Order”

Strategy R Select the maintenance strategy A for time based maintenance strategy

Press the enter key to get the following screen



In the screen , enter the values in the following fields.



Description R Enter the Maintenance Plan descriptionReference Object:Functional Location

O/R Reference object on which the maintenance activity should be carried out.

Equipment O/R Reference object on which the maintenance activity should be carried out.After selecting equipment press enter key so that system selects data from the master.

Planning Plant R Enter Planning Plant if you selected the equipment then system call default values from the master.

Main Work Center Enter the Main Work CenterOrder Type R Enter Maintenance Order type:-Ex M1 on which the

maintenance call objects will be created.Task List O Assign a Task List either general equipment of

functional location task list.



Click on icon to reach the following screen.

In the screen , enter the value in the following fields:-



Call horizon O % of scheduling period that should be consider in planning.if nothing is mentioned 100% will be considered.

Scheduling Period O Planning period during which call objects will be created as per the cycle duration.

Start Of Cycle O Enter the date on which the planning cycle should start.

Click on to save the created single cycle plan


Call Horizon- Here fill percentage when the call to be come for maintenance . Example:- If cycle=100 days , & call horizon=90% , means at 90th day we will receive the order , for planning the man & material required to complete the maintenance order.Scheduling Period -Now we will fill the maintenance plan scheduling parameters i.e the time for which we will schedule this plan.Example- If we take sch. Period 10 year then total 10 nos maintenance order will generate with yearly cycle


After enter all require values , click on to save the notification and following message will be given by the system.

Maintenance Plan Scheduling

Once the maintenance plans are created , then these plans are scheduled. It is important to input “Start date” or “Starting counter reading” in the individual maintenance plan.This date or counter reading decides the schedules dates.

Scheduling can be done manually as well as by system . It is recommended to the scheduling by system to avoid manual errors. Whenever a schedule falls due , the system creates a maintenance order , notification or service entry sheet depending on definition of the call object of the plan.

The maintenance planner shall schedule the maintenance plan . Before the call objects are created by the system , maintenance planner may manually call the job or skip the job , depending on the situation.

Module: PM Title:Maintaining of Master date-EquipmentTransaction Code: Create:IP10

Menu Path: Logistics Plant Maintenance Preventive maintenance Maintenance Planning Scheduling for Maintenance Plans Schedule (IP10)

Double click on to reach the following screen.



Input the maintenance plan number and click on enter key.


Click on start button to schedule the maintenance plan

\ Enter the cycle start date &Press enter


Click on Save

Deadline Monitoring:-

SAP Menu SAP Menu---Logistics---Plant Maintenance---Preventive Maintenance---Maintenance Planning---Scheduling for Maintenance plans---Deadline Monitoring

T Code Type IP30 in Command Field and press




Input the Maintenance plan number and enter the number of interval days for Call objects and click on

Execute


List Of Call Objects:-

SAP Menu SAP Menu---Logistics---Plant Maintenance---Preventive Maintenance---Maintenance Planning---Scheduling for Maintenance plans---Scheduling Overview---List Display

T CodeType IP24 in Command Field and press


Input the Maintenance Plan Number and Notification type and Click on Execute


As we Schedule the maintenance plan notification will create automatically in back-end then Process the notification.

Process Notification:-

Module: PM Title:Notification ProcessTransaction Code: Type IW22 in Command Field and press

SAP Menu---Logistics---Plant Maintenance---Maintenance Processing---Notification---Change

Input the Notification number and click on Enter



In the above screen the system status is OSNO (Out standing Notification) to change the status

from OSNO to NOPR (Notification in Process) click on Release (Green Flag)



Click on Save

And System Will generate a message like below screen.

After the above step Decide on the requirement of Maintenance order, based on material to be consumed from stores or need based services to be used.

Follow the below steps to Create the Maintenance order from Notification and for further processing.

Create Maintenance order from Notification:-

Module: PM Title:Maintenance Order ProcessTransaction Code: Type IW22 in Command Field and press

SAP Menu---Logistics---Plant Maintenance---Maintenance Processing---Notification---Change



Input the Notification Number and click on Enter

System will prompt for a pop-up window as below


Click on Icon to create the order


Check all the details and click on Continue

Click on Save

And System Will generate a message like below screen.

Maintenance Order of Order Type “PM02” created and linked to the Notification. Status of Notification will be updated to “ORAS” (Order Assigned).



Material Planning Against Maintenance Order:-

Module: PM Title:Maintenance Order ProcessTransaction Code: Type IW22 / IW32 in Command Field

and press

SAP Menu---Logistics---Plant Maintenance---Maintenance Processing---Notification---Change or SAP Menu---Logistics---Plant Maintenance---Maintenance Processing---Order---Change

From Tcode IW32

Input the order number and click on continue .




Click on “Components” Tab


If you want to see the reservation number double click on “0010”

Now Release the order by clicking on the Green Flag



Click on Save .

System will generate following message.

Material Issue against Reservation:-

Module: PM Title:Material IssueTransaction Code: Type MIGO in Command Field and

press

SAP Menu---Logistics---Materials Management---Inventory Management---Goods Movement---Goods Movement


Select the Goods Issue from the drop down, Input the Reservation number generated in the

maintenance order and click on Execute Button


Click on Line item 1 and input the storage location from which you want to issue the material and select Item OkEnter the movement type in which cost center material will be consume.Same as above select the Line item 2 and input the storage location and click on Item Ok

Note: If you want to know in which storage location the material is stored click on

After all the input Click on Check

You will find the green traffic lights if the input data is correct and then click on Post

Maintenance Order Confirmation:-

Module: PM Title:Maintenance Order ProcessTransaction Code: Type IW41 in Command Field and press

SAP Menu---Logistics---Plant Maintenance---Maintenance Processing---Completion Confirmation---Entry---Individual Time Confirmation



Enter all the details like Work Centre, Personnel number, Actual work, Actual duration, Work starts on, Work Ends on, Reason, and Confirmation Text

After all the details are maintained click on


Input the Order number which you want to confirm and click on continue or press the enter key on keyboard

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UM Preventive Maintenance