SAP – PM End User’s Training
Plant Maintenance Universal Process Model (UPM)
Plant Maintenance Universal Process Model (UPM)
Asset Management Structure
Asset Maintenance Management Conduct budget control Perform intercompany spare parts sales Measuring Point (PM & Fleet)
Project execution for assets Conduct order managed modifications Install capital equipment Dismantle equipment
Preventive / Predictive Maintenance Perform preventive / predictive maintenance
Corrective maintenance Conduct unplanned/emergency breakdown maintenance Perform low cost repairs Perform Planned Repairs Refurbish spare parts
Asset Management Processes
• Broken up into 4 Core Process Functions
– 1) Asset Maintenance Management
– 2) Execute Projects for assets
– 3) Preventive/Predictive Maintenance
– 4) Corrective Maintenance
Asset Management
Asset Maintenance Management
Project Execution For Assets
Preventive/ Predictive
Maintenance
Corrective Maintenance
Asset Maintenance Management
• Conduct Budget Control – Depending on the implementation within the
company, budgetary control measures can be set up at cost center level or for the maintenance order itself. At individual maintenance order level, a budget can be set and once the budget has been reached, no more costs can be accumulated against that order. The budget can be changed with the necessary authorization
• Perform Intercompany Spare Parts Sales - – Within R/3, the stock of spare parts can be
viewed across plants. It is however, important to ensure that there is standardization relating to the relevant master data of the parts.
• Measuring Point (PM & Fleet) - – measurement documents are created against
the assets that allow for follow up activities in invoicing and managing fuel usage against distance incurred (Fleet)
Asset
Management
Asset Maintenance Management
Project Execution For Assets
Preventive/ Predictive
Maintenance
Corrective Maintenance
Conduct Budget Control
Perform Interco.
Spares Sales
Measuring Points
(PM & Fleet)
• Conduct Order Managed Modifications - – A modification to equipment is made to
improve its performance or to prolong its usable life. This is a planned intervention, for which a cost estimate and approval is required. This process adds value back to the asset.
• Install Capital Equipment - – Maintenance departments are commonly
used to assist with the installation of Capital Equipment. This process describes the use of the Maintenance Order to procure the equipment and the settle it to WBS elements and the settlement of the labor to expense cost elements.
• Dismantle Equipment - – Within Capital Projects, an expense portion
can exist in the dismantling or demolition of the equipment. This process make use of the Maintenance Order to accomplish. It also triggers the need for asset disposition and changes to functional location structures
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Order Managed
Modifications
Install
Capital
Equipment
Dismantle
Capital
Equipment
Project Execution for Asset
Preventive/Predictive Maintenance
• Perform Preventive/Predictive Maintenance – Process allows for the development of
routine and repetitive pre-scheduled maintenance activities • Support Reliability Principles • Support Operational Excellence
Methodologies • Flexible for PM Optimization
activities • Flexible to institutionalize PMs based
upon COE Successful Practices • Options for Time Based, Performance
Based, and Condition Based PMs available
• Can be set to single cycle, multi-cycle, or a combination of both
• Can be used to manage EOSH routine activities
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Preventive/
Predictive
Maintenance
Corrective Maintenance
Processes support both Reactive and Proactive Corrective Maintenance activities:
Perform Emergency Repairs -
o In this process the steps before completion of the work are minimized so efforts go towards resolving
issues associated with the emergency. After completion of the repair, history is then gathered.
Perform Low Cost Repairs -
o In this process, a standing order is created to capture confirmed activities to repair minor stops and
short duration fixes.
Perform Planned Repairs -
o Newly created to enable and institutionalize the COE’s best practice Proactive Maintenance Planning
and Scheduling processes
Refurbish Spare Parts w/Split Valuation -
o This process deal with the refurbishment of - usually high value - faulty repairable spares. This is of
considerable economic importance for our bottlers and is often a core process in Plant Maintenance. It
is often much more cost-effective than a brand new purchase.
Reacti
ve
P
roacti
ve
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Perform
Emergency
Repairs
Perform
Low Cost
Repairs
Perform
Planned
Repairs
Refurbish
Spare Parts
Asset Management
• These 4 Core Process Functions, Asset Maintenance Management, Execute Projects,
Preventive/Predictive Maintenance, & Corrective Maintenance, now provides us the Asset
Visibility to:
1. Reduce Operating Cost by improving Labor utilization
2. Reduce Operating Cost by better managing parts and services
3. Reduce the Asset swell in spare parts by better management locally, regionally, and
globally, bring down unproductive inventory values
4. Reduce spend on spare parts procurement
5. Reduce the need to procure more capital
6. Focus on key Assets that provide the best opportunity to add availability and capacity
without adding capital
7. Increase Efficiency’s
8. Increase Throughput
9. Reduce other Supply Chain costs
10. Ultimately improve the Return on Assets involved in the Make Process of Finished
Goods
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Plant Maintenance Technical & Object data & Base Requirements
Required Organizational Entities
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According the Systems Applications and Products (SAP) standard organizational objects, the business scenario is mapped as follows:
General organization Location-based organization Planning-based organization
(i.e. oil & gas
company)
Required Organizational Entities
Company Codes
• Company codes generally represent the various legal entities within an organization. The Company Code is the lowest level for which you can produce a complete set of financial reports.
• There is no PM configuration in this area.
Plants
• In the Enterprise Resource Planning (ERP) System, the plant is a place of work or a branch within a company. The plant is integrated in the organizational structure as follows One plant (i.e. plant -0001) is assigned to exactly one company code (i.e. Company - 1000). One company
code can have several plants.
One plant can have several storage locations at which materials stocks are stored
Exactly one business area is assigned to a plant and a division
A maintenance plant can be defined as a planning plant
• A plant has the following attributes:
It has an address.
It has a language.
It belongs to a particular country.
It has its own material master data.
.
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Required Organizational Entities
Maintenance plants and planning plants
• The maintenance plant of a technical object is the plant in which the object is installed.
• The planning plant of a technical object is the plant in which the maintenance tasks for that object are planned and prepared.
Planner groups is part of the planning plant which prepare a tasks for the technical object in maintenance plants
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Required Organizational Entities Planner Groups
• Planner Groups are also organizational structure units. This is typically localized, but customization and logic to other functions such as notification screens and printing uses standard Planner Groups for PM to provide added functionality.
• The below have been set up in the system to be maintained .
• Planner groups can move to being plant specific because of segregation from CAM
Work Centers
• Work Center (Location Tab) is defined as an
organizational unit that assigns where the technical object is located.
• This is the Production Planner (PP) Work Center and not the Maintenance Work Center which is usually associated to labor.
• Where possible in Equipment Record and Functional Location Record this field should be populated. This require obtaining the PP Work Center information for populating this information in advance or as a dependency during load.
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Required Organizational Entities
Storage Locations
• The Storage Location is defined as an organizational unit, allowing for differentiating between the various stocks of a material in a plant.
• Specified amounts of materials can be moved between different storage locations.
• A Storage Location is typically represented by a plant-unique 4-digit alpha-numeric.
• Material stocks can be differentiated, on a quantity basis, within one plant according to storage location.
• Storage locations are always created for a plant.
• Physical inventories are carried out at storage location level.
• For Coke One, common storage locations have been set up for each plant.
Plant Section
• Plant Section is generally considered a local
organizational unit. It is used to further breakdown a Maintenance Plant into physical or logical functions.
• Guidance is given in this area as the Plant Section is also used in the Functional Location structure to provide consistency in analysis of various plants in the BIG.
• There is no straight forward way to standardize this organizational unit as each plant has its own unique differences and configuration. The below provides guidance to selecting the Plant Section number.
010 – 019 General Plant Services, Building & Grounds
020 – 029 Bottle /Can Sorting & Delivery Systems
030 – 039 Blending & Mixing Production & Packaging
040 – 049 Production & Packaging
050 – 059 Warehousing and Logistics
060 – 069 Trade Services
070 – 079 Fleet
080 – 089 Office & Support Functions
090 – 099 Redeployable Asset
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Required Data Elements - Functional Location • The structure indicator of a functional location determines the structure of the functional location label. It
establishes the following factors: Number of hierarchy levels of a technical system Key length of the levels Separators (hyphens)
• For Coke One, the Structure Indicator is ZSTD. The edit mask assigned to it is:
NNNN-NNN-NN-NNN-NNNNN
NNNN = Plant Code (i.e., 0000 = Singapore’s Plant Number) Spatial NNN = Plant Section (i.e., 010 = Manufacturing Bldg) Spatial and Process-based NN = Type of Line or Process (i.e., 01 = Production Area) Process-based NNN = Plant Line # or Plant Process# (i.e., 001 = Line 1) Spatial NNNNN = Equipment /System Function (i.e., 00100 = Filler) Functional
Example above = 0001-010-01-001-00100
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Perform Preventive Predictive Maintenance - Master Data
SAP – Technical & Object data & base requirement
1. Work Center List Display (CR05)
2. Functional Location Structure Display (IH01)
3. Equipment List Display (IE03)
4. Function location master data Display (IL03)
5. Equipment master data Display
Asset Maintenance Management
Asset Management
Asset Maintenance Management
Conduct budget control
Perform intercompany spare parts sales
Measuring point (PM & Fleet)
Project execution for assets
Conduct order managed modifications
Install capital equipment
Dismantle equipment
Preventive / Predictive Maintenance Perform preventive / predictive maintenance
Corrective maintenance Conduct emergency breakdown maintenance
Perform low cost repairs
Perform Planned Repairs
Refurbish spare parts
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Budget
Control
Perform
Interco.
Spares Sales
Measuring
Points
(PM & Fleet)
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Measuring Points and Counters
A Measuring point is Master Data created for a Technical Object in order to document a Measurement or a Counter reading. This is done for one of three reasons:
You want to document the condition of a technical object at a particular point in time.
You want to perform Counter Based Maintenance (Preventive).
You want to perform Conditioned Based Maintenance (Predictive).
In the case of Counter Based Maintenance, maintenance activities are scheduled to be performed when the Counter of the Technical Object has reached a particular Counter Reading, for example, every 100 Operating Hours.
In the case of Condition Based Maintenance, maintenance activities are scheduled to be performed when the Measuring Point of a Technical Object has reached a particular state, for example, every time a brake pad has been worn away to the minimum thickness permitted, or when the cooling water for a Nuclear Power Plant exceeds the upper limit allowed.
The Measuring Point must have a Characteristic assigned to it.
18
Fleet Measuring Point (KM & Fuel Consumption reading)
Asset
Management
Measuring
Points
(PM & Fleet)
Create Equip
Create Measuring
Point Close
Asset
Maintenance
Management
Fleet Measuring Point (KM & Fuel Consumption reading)
SAP - Processing of Measurement Points process
flow
1. Display equipment master for vehicle w/ Measuring point (IE03)
2. Display & Changes measuring point list (IK32) i.e. 2000011
3. Reading entry (IK34)
Asset Maintenance Management
Asset Management
Asset Maintenance Management
Conduct budget control
Perform intercompany spare parts sales
Send fuel card information
Project execution for assets
Conduct order managed modifications
Install capital equipment
Dismantle equipment
Preventive / Predictive Maintenance Perform preventive / predictive maintenance
Corrective maintenance Conduct emergency breakdown maintenance
Perform low cost repairs
Perform Planned Repairs
Refurbish spare parts
Asset
Management
Asset
Maintenance
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Conduct
Order Managed
Modifications
Install
Capital
Equipment
Dismantle
Capital
Equipment
Conduct Order Managed Modifications
Asset
Management
Project
Execution
For Assets
Order
Managed
Modifications
Request for project modificati
on
Finance Approval for WBS
Notification
approved
Create order & release
Confirmation
Close order &
Notification (TECO)
Finance settle to
WBS
Conduct Order Managed Modifications
A modification to equipment & function location is made to improve its
performance or to prolong its usable life. This is a planned intervention, for which a cost estimate and approval is
required. This process adds value back to the asset.
Conduct Order Managed Modifications
SAP - Order Managed Modifications process flow
1. Create Project request (IW21) 2. Create CapEx order & release (IW31) 3. Order Confirmation (IW41) 4. Close order & notification (TECO) (IW41) 5. Display WBS (CJ03)
6. WBS Expenses /Budget, Plan & Actual cost report (S_ALR_87013558)
Install Capital Equipment
Asset
Management
Project
Execution
For Assets
Install
Capital
Equipment
Install Capital Equipment
Maintenance departments are commonly used to assist with the installation of Capital Equipment. This process describes the use of the Maintenance Order to procure the equipment and the settle it to WBS elements and the settlement of the labor to expense cost elements. Request
for project installatio
n
Finance Approval for WBS
Notification
approved
Create order & release
Confirmation
Close order &
Notification (TECO)
Finance settle to
WBS
Install Capital Equipment
SAP – Install Capital Equipment process flow
1. Install Capital Equipment (IE02)
Dismantle Equipment
Asset
Management
Project
Execution
For Assets
Dismantle
Equipment
Dismantle Equipment Within Capital Projects, an expense portion can exist in the dismantling
or demolition of the equipment. This process make use of the
Maintenance Order to accomplish. It also triggers the need for asset
disposition and changes to functional location structures
within R/3.
Request for
Dismantle
Finance Approval for WBS
Notification
approved
Create order & release
Confirmation
Close order &
Notification (TECO)
Finance settle to
WBS
Dismantle Equipment
1. Dismantle Equipment Process (IE02)
SAP – Dismantle Equipment process flow
Preventive/ Predictive
Maintenance Asset Management
Asset Maintenance Management
Conduct budget control
Perform intercompany spare parts sales
Send fuel card information
Project execution for assets
Conduct order managed modifications
Install capital equipment
Dismantle equipment
Preventive / Predictive Maintenance Perform preventive / predictive maintenance
Corrective maintenance Conduct emergency breakdown maintenance
Perform low cost repairs
Perform Planned Repairs
Refurbish spare parts
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Preventive/
Predictive
Maintenance
Perform Preventive/Predictive Maintenance
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Preventive
Maintenance
Maintenance Plan
Schedule the Plan
Create PM Orders
Adjust planned
dates if required
Release the Order Execute Maintenance
Maint. Operation
Confirmation
Technically complete
the order
Record technical data
in notification
Complete notification
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Strategy plan
Time-based Performance-based
Maintenance plans
Perform Preventive Predictive Maintenance
Preventive Maintenance Plan: Structure
Maintenance items
Preventive
maintenance plan
Maintenance
Schedule
Maintenance orders
Preventive
Maintenance
strategy
Maintenance
task list
Maintenance items
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Maintenance
Package
Perform Preventive Predictive Maintenance
Perform Preventive Predictive Maintenance
SAP - Preventive maintenance process flow
1. Maintenance Strategy Display (IP12)
2. General Maintenance Task List Display (IA07)
3. Maintenance Plan Display (IP03)
4. Maintenance Plan Scheduling Display/Reschedule/Manual Call (IP10)
5. Generating and list of orders IP30&IW38
Corrective Maintenance
Asset Management
Asset Maintenance Management
Conduct budget control
Perform intercompany spare parts sales
Send fuel card information
Project execution for assets
Conduct order managed modifications
Install capital equipment
Dismantle equipment
Preventive / Predictive Maintenance Perform preventive / predictive maintenance
Corrective maintenance Conduct emergency breakdown maintenance
Perform low cost repairs
Perform Planned Repairs
Refurbish spare parts
Asset
Management
Asset
Management
Management
Project
Execution
For Assets
Preventive/
Predictive
Maintenance
Corrective
Maintenance
Perform
Emergency
Repairs
Perform
Low Cost
Repairs
Perform
Planned
Repairs
Refurbish
Spare Parts
Conduct Emergency Breakdown Maintenance
Asset
Management
Corrective
Maintenance
Emergency
Breakdown
Maintenance Break
down
Notification & Release
Work Order & Release
Confirm
TECO
Conduct Emergency Breakdown Maintenance
1. Create PM Notification- ZU (IW21)
SAP - Emergency Breakdown process flow
2. Create Order & Release (IW31)
3. Order Confirmation (IW41)
4. TECO (IW32)
37
Perform Low Cost Repairs
• Within a limited range, a technician may confirm times, and only times, to a standing order as long as there is no goods issue involved (no spare parts consumed).
• If a goods issue is involved or the time limit is exceeded, the technician has to trigger the release process for a notification and order.
• The work order is only open for a specified time period
• Notifications are created for low cost jobs and linked to the open work order
Asset
Management
Corrective
Maintenance
Perform
Low Cost
Repairs
• Create Standing Work Order (ZP)
• Create Notifications (ZU)
• Assign Notifications to Standing Work Order
• Confirm Notifications
•
Standing Order
Low Effort Not.
Assign
Not. To
Order
Confirm
Close
Order
Perform Low Cost Repairs
Perform Low Cost Repairs
Low Cost Repairs – Process flow
2. Create PM Notification (Low cost assign to order) (IW21)
1. Create Order & Release – Open order, ZP03(IW31)
3. Operation Confirmation (IW41)
5. TECO (After 6M or 1Y) (IW32)
4. Notification close – (after job is done) (IW32)
Perform Planned Repairs Process Flow
Asset
Management
Corrective
Maintenance
Perform
Planned
Repairs Problem
ID’d
Notify
Create
WO
Plan
WO
Schedule
WO
Execute WO
Doc & Close
Perform Planned Repairs
SAP - Planned Repairs process flow
1. Create PM Notification- ZP - (IW21)
2. Create Order & Release (IW31)
3. Order Confirmation (IW41)
4. TECO – Order & Notification close (IW32)
Refurbish Spare Parts
Bought stock and
put into spares
Special type of
maintenance
order
Broken Item
Broken Item
Asset
Management
Corrective
Maintenance
Refurbish
Spare
Parts
• High value materials or spare parts, such as motors, are often used in production systems. In the event of failure or damage to these types of parts, they may be replaced by a functioning spare, then refurbished in the maintenance department or externally if deemed more cost effective to do so. Refurbishment is frequently considered more cost effective and should be applied when this is the case. The cost to process the routine has to be weighed also, considering planner time, purchaser time, and storeroom attendant time. With this in mind, as a guideline, spare parts having an individual value of 500 Euros or more (roughly $750) should only be considered for refurbishment. Only in special cases should other parts be put into the refurbishment process.
• In typical corrective maintenance repair processes, some described above, work order are set for the consumption of materials or parts. In the refurbishment process, work orders are intended to repair the defective part. To accomplish this, the refurbishable material has to be classified by 3 different states, called valuation types. They are: New, Refurbished, and Defective. The valuation types have been set up in the system as:
•
Refurbish Spare Parts
Asset
Management
Corrective
Maintenance
Refurbish
Spare
Parts
Refurbish Spare Parts
Refurbish Spare Parts
SAP - Refurbishment of spare parts process flow
1. Create Order & Release – (IW81)
2. Order Confirmation (IW41)
3. TECO – Order close (IW32)
Material Masters
• The material master contains descriptions of the articles and parts that the plant, manufactures, and
stores. The material master is the central source for calling up material specific information within the plant. Since all the material data is integrated in one master record, the problem of data redundancy is minimized. This integration also enables the stored data to be used jointly by purchasing and other areas such as Inventory Management, Material Request Planning (MRP), and Accounts Payable.
• Plant Maintenance uses the following Material Types.
ZDIE SCALE Services
ZENS PM Spares Non Standardized Local
ZESS PM Spares Standardized Global
ZIMA Maintenance Assemblies
ZNFA Fixed Assets
ZNNM Non-Stock Materials
ZNVM Non Valuated Material
45 45
Material Masters
SAP – Stock Item process flow
1. Materials List Display (MMBE)
2. P.R. List Display (MN53N)
3. P.O. List Display (ME23N)
Order - with Stock Item material
Released Planned Wos
(ZP01, ZP03, etc)
Work Order
0010 Check pump
0020 Renew seals Material
Issue/ Pick Lists
Problem
ID’d
Create Notificatio
n & Release
Create order (+ Materials) &
released
Received materials
Confirm order
TECO & Close Order
Material
SAP – Stock Item process flow
1. Create Notification & Release (IW21)
3. Goods Receive Process (MIGO) 4. Confirm order (IW41)
5. TECO and close order (IW32)
2. Create order, Add material & Release order (IW32)
Order - with Non-Stock Item Material
Released Planned Wos
(ZP01, ZP03, etc)
Work Order
0010 Check pump
0020 Renew seals Material
Issue/ Pick Lists
Problem
Create Notificati
on & Release
Create order (+ Materials) & released
PR Created Automatically
Received materials
Confirm order
TECO & Close Order
Material
SAP – Non-Stock item maintenance process flow
1. Create Notification & Release (IW21)
3. PR Created automatically 4. Good Receive (MIGO)
5. Confirm order (IW41)
2. Create order, Add material & Release order (IW32)
6. TECO and close order (IW32)
END