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Presentation Title | Confidential | Document ID | Apr 8, 2023 2

PLANT MAINTENANCE SYSTEM

SAP R/3


I. MANAGING MASTERS

II. MANAGING MAINTENANCE PROCESSES

III. MANAGING REPORTS

PLANT MAINTENANCE SYSTEM


I. MANAGING MASTERS


MAINTENANCE MASTERS

BASIC MASTERS

1. Functional Locations

2. Equipment Master

3. Class & characteristics

4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

CONTENTS OF MAINTENANCE OF MASTERS

• Plant• Main Planner Group• Plant Section• Main Work Center• Cost Center /Internal Order• Category• Company Code• Strategy• UOM


MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

CONTENTS OF MAINTENANCE OF MASTERS

• Function Location Structure

• Function Location Category

• Plant


Functional locations Structure is a hierarchical Presentation of a Tech.

System.

Gives information about how the Technical System is sub divided into

Individual Functional Units.

Individual function Units are defined on the Basis of Process Orientation,

Functions, or any other Special criteria. Each functional location is managed independently in the system, so that you can :

• Manage individual data from a maintenance perspective for the object• Perform individual maintenance tasks for the object• Keep a record of the maintenance tasks performed for the object• Collect and evaluate data over a long period of time for the object

FUNCTIONAL LOCATION STRUCTURE


FUNCTION LOCATION STRUCTURE

Description Code

Structure Indicator GIL

Structure Indicator Text GIL Cement Division

Edit Mask AAA-AANN-AAX-AAX-XXX-XXXXX

Hierarchy Levels 1 2 3 4 5 6

Hierarchy Level

Edit Mask Code Description

Level 1 AAA GIL Grasim Industries Limited

Level 2 AANN RC01 Raja shree Cement

Level 3 AAX RC1 Raja shree Cement Unit-I

Level 4 AAX CM1 RC1 Cement Mill-1

Level 5 XXX FEG RC1 Cement Mill -1 Feeding Group

Level 6 XXXX

Example


MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

CONTENTS OF FUNCTIONAL LOCATION MASTER

• Function Location Structure

• Function Location Category

• Plant


FUNCTION LOCATION CATEGORY

Category Description

C Colony Functional Locations

G General Functional Locations

H Hierarchical

M Plant & Machinery F Locations

N Mines Functional Locations

O Office Functional Locations

T Power Generation F. Locations

U Utility Functional Locations


Display of Function Location-[IL03]

List Editing of Function Location-[IH06]

Display ( Multi Level) Function Location[IL07]

DISPLAY CONTENTS: Display Action Log

Object Information

NAVIGATE > SAP SCREEN


MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF MAINTENANCE OF EQPT MASTER

Equipment Category Plant Functional Location Main Planner Group Tech. Object Type Plant Section Main Work Center Cost Center /Internal Order Company Code Class Warranty data


Defining Equipment Categories is a facility in SAP/PM to

group the vast variety of Equipments that any manufacturing

Organization can have in their Plant. One of the methods of

grouping similar Equipments is to differentiate them on the

basis of their Use and / or the Function that they perform e.g.,

Electrical Equipment. In GIL, this is the basis of defining

Equipment Category shown in the next two slides

EQUIPMENT CATEGORY


CATEGORY

EQUIPMENT EXAMPLES

A AUTOMOBILE CARS/JEEP/MOBILE VAN

C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS

D DUMMY EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR TRANSFER. NOT TO BE USED

E ELECTRICAL EQUIPMENTS MOTORS/TRANSFORMERS/SWITCH GEARS

I INSTRUMENT EQUIPMENTS RTD’S/PROXIMITY SWITCHES/FIELD INSTRUMENTS/PANELS

M MECHANICAL EQUIPMENTS GEAR BOXES/DPC/DBC/BELT CONVEYORS

N MINES EQUIPMENTS SHOVELS/DUMPERS/DRILLING MACHINES

EQUIPMENT CATEGORY


CATEGORY

EQUIPMENT EXAMPLES

P PROCESS EQUIPMENTS CYCLONES/HOPPERS

Q QC TEST EQUIPMENTS CUBE TESTING MACHINE / COMPRESSIVE STR MACHINE

R PRODUCTION RESOURCES/TOOLS CRANES

T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER

U UTILITY EQUIPMENTS COMPRESSOR/WATER PUMPS

NOTE:

ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO

TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT

CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.

EQUIPMENT CATEGORY


EQUIPMENTS CATEGORY & NUMBER RANGE

Category

DescriptionNumber range

From

Number Range To

M Mechanical Equipments 10000000 19999999

E Electrical Equipments 20000000 29999999

I Instrumentation Equipments 30000000 39999999

P Process Equipments 40000000 49999999

T TPP & DG Equipments 50000000 59999999

N Mines Equipments 60000000 69999999

AAutomobiles Equipments

70000000 79999999

C Civil Objects & General Equipt. 80000000 89999999

S Safety Equipments 90000000 99999999

Q QC Test Equipments 1000000 1999999


Technical Object Types are the logical grouping of Objects on the

basis of similarity of function being performed by each one.

Examples :

ME_GEARBOX Gear Box

EL_MOTORS Electrical Motors

ME_FANS Fans

TECHNICAL OBJECT TYPE


Plant in which maintenance tasks are planned and executed. In GIL ,

Planning Plant is also a Maintenance Plant. Different Planning Plants in GIL

are :

Aditya Cement

Grasim Cement

Vikram Cement

Rajashree Cement

Grasim South

Birla Super Cement (Hotgi)

Birla Plus Cement (Bhatinda)

PLANNING PLANT


MAIN WORK CENTER

Main Work Center is Logical Grouping of all Work Centers, which are

Performing similar nature of Maintenance Tasks/Activities in different

Plant Sections. E.G. Mechanical Main Work Center is a Group of Plant

Maintenance Persons, who are executing Mechanical Maintenance

activities . Different Main Work Centers defined are :

• Mechanical Department

• Electrical Department.

• Instrumentation Department.

• Process Department.

• Civil Department, Etc.


Plant Section is a division of Maintenance Plants into Production

Areas.

PLANT SECTION

DescriptionCategory Plant

Packing Plant -1 PP1GC01

Cement Mill -1 CM1GC01

Kiln -1 KL1GC01

Coal Mill -1 CO1GC01

Raw Mill -1 RM1GC01


PLANNER GROUP

Planner Group defines the Group of People (Employees) responsible for Planning and Execution of Maintenance Activities in a Particular Plant.

PLANNER GROUP CODIFICATION LOGIC

PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION

MCM = Mechanical + Cement Mill

ECM = Electrical + Cement Mill

ICM = Instrumentation + Cement Mill


COST CENTER/ INTERNAL ORDERS

Cost Centers are logical Organizational Units where the costs are incurred for value addition . Costs incurred are ultimately settled to Cost Centers through Orders.

Internal order is nothing but an intermediate cost collector between PM order and cost center. Internal Order will be used in Mines Equipment only.

Cost Center Concept as applied in GIL :

Plant Section = Superior Cost Center

Department = Sub Cost Center in that Plant section

CEMENT MILL

Mechanical ProcessElectrical Instrumentation


Creation of Equipment-[IE01] Change of Equipment-[IE02] Display of Equipment-[IE03] List Editing of Equipment-[IH08] Display ( Multi Level)-[IE07]

DISPLAY CONTENTS:

Display of Usage List Display Action Log Display Object Information Installation & Dismantle



MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF CLASS & CHARACTERISTICS MASTERS

Class Type

Class Group

Characteristics Group

Unit of Measure for

Characteristics Master


Classes are :

Logical Grouping of Equipments having Similar Functions. Class Mainly Depends on the Main Function / Activity being

Performed by that Equipment. It helps to know the Number of Equipments having the same

Class. Class data will never Change throughout the entire Productive

Life-Cycle of the Equipment. This information can be used for Proper Planning of Spares,

for planned Maintenance & obtaining the History of that Class of Equipments.

CLASS


Characteristics are the Specifications or Designed Parameters of Measurement for the Equipments. Ex. Flow of Fan , Gear Ratio of Gear Box.

Combination of Class and Characteristics helps in Precise search of Equipments.

For Example:

Select Gearbox of Particular Make / Ratio. Select Class as Gearbox & Characteristics as Make/ Ratio. Enter

Relevant Values of these Characteristics. System will search & display all Gearboxes satisfying above

Characteristics Values

CHARACTERISTICS


CLASS

Class Description

GEARBOX GEARBOX

BUCKETELELVATOR BUCKET ELELVATOR

BALLMILL BALL MILL

BAGHOUSE BAG HOUSE

Class Description

LTMOTOR LT MOTOR

LTFEEDER LT FEEDER

BATTERY BATTERY

BREAKER BREAKER

Mechanical Electrical


CLASS AND CHARACTERISTICS GROUPS CODES

Class Group Code DescriptionPM_EQ_ELEC PM Elec. Equipments Specs. Class Group

PM_EQ_GENL PM General Equip. Specs. Class Group

PM_EQ_INST PM Inst. Equipments Specs. Class Group

PM_EQ_MECH PM Mech. Equipments Specs. Class Group

PM_EQ_MINE PM Mine. Equipments Specs. Class Group

PM_EQ_PROC PM Proc. Equipments Specs. Class Group

PM_EQ_TPDG PM TPP & DG Equip. Specs. Class Group

SA_EQ_SAFE PM Safety Equip. Specs. Class Group

Char. Group Code DescriptionPM_EQ_ELEC PM Elec. Equipments Specs.Char. Group

PM_EQ_GENL PM General Equip. Specs. Class Group

PM_EQ_INST PM Inst. Equipments Specs.Char. Group

PM_EQ_MECH PM Mech. Equipments Specs.Char. Group

PM_EQ_MINE PM Mine. Equipments Specs.Char. Group

PM_EQ_PROC PM Proc. Equipments Specs.Char. Group

PM_EQ_SAFE PM Safety Equip. Specs. Char Group

PM_EQ_TPDG PM TPP & DG Equip. Specs. Char. Group


Display of Class List [CL03]

Find Object in Class- [CL30N ]



MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF MIC’s MASTER

Plant

Range of Characteristics Value


MASTER INSPECTION CHARACTERISTCS

Specific parameters of an Equipment for Calibration

Parameters to measure whether Equipment is performing its function

The Parameter driving / governing Equipment performance/Output is

within acceptable limits.

Example: Mili-amperes / Mili-volts for weigh Feeder


Find out The Maintenance Inspection Characteristics prepared-[QS24]



MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF WORK CENTER MASTER

Plant

Work Center Category

Control Key

Cost Center

Work Dimension - Time

Work Unit


WORK CENTER

Work Center is a Person/Group of Persons, who perform Maintenance Activities.

Work Center Category

Each Department will have two categories, Permanent and Contractor.

Category Description

0021 Mechanical Permanent

0022 Mechanical Contractor

Example : M1F1W3K, MC1F1W3K etc.

Codification Logic :

M1F1W3K = Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi

MC1F1W3K = Mech. Contractor / 1 Fitter /1Welder / 3 Khalasi



Work Center List-[IR03]

DISPLAY CONTENTS: Relevant Number for Permanent and Contractor Work centers

for your department. Different combinations of Skills.


MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF MEASURING POINT MASTER

Equipment Master

Function Location Master

Category of Measuring Point

Characteristics

Unit of Measures


It is a Measurement characteristic/Parameter attached to an Equipment

Describe the Physical and/or Logical Locations of Equipment

at which a Condition / Parameter is to be measured.

Measuring Point will be always for an Equipment or FL or assembly

but Generally for Equipments.

Measurement readings are taken for an Equipment at regular

interval to know the Condition at that time.

MEASURING POINT


Measuring Point is also Used as Counter where values Measured by a Measuring Point can be summed up during a time period for monitoring and control .

Example:

Running hours of Any Equipment

Lubrication Consumption.

MEASURING POINT Continued..


NAVIGATE > SAP SCREEN(MP)

Creation Of Measuring point [IK01 ]

Change / Display Of Measuring Point [IK02/ IK03]

Display List Editing-[IK07]

Create Entry List-[IK31]

Collective entry of measuring document-[IK34]

DISPLAY CONTENTS:

Transfer of Measuring point


MAINTENANCE MASTERS

BASIC MASTERS

1. Function Locations

2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF TASK LIST MASTERS

Group Coding

Counter

Planning Plant

Maintenance Strategy

Work Center

Set of Operations

MIÇ’s


TASK LIST

A Set of Activities to be Performed on an Equipment or Functional

Location.

Three types of Task Lists : Functional Location Task List[T] Equipment Task List[E] General Task List[A]


seq Codification Logic for defining Task List Group - It has to be Planning Plant / Maintenance Specific

1 XX GIL Plant Short Code:

RC = RC01, GS = GS01, GS = GS01, GC = GC01, BS = BS01.

2 X Discipline:

E = Electrical, M = Mechanical, I =Instrumentation, P = Process, N = Mines, T = TPP, Q = QC,S = Safety

3 XX Equipment Short "Equipment Class Code":

GB = Gear Box, BF= Bag Filter, BC = Belt Conveyor, AT = Analyzer, MO= DC Motor, etc

4 X Equipment Class Code Type( application) :

GB Gear Box Helical; Radial; BE-Bucket Elevator Belt/ Chain

5 XX Type of Maintenance Task List:

PM=Preventive Maintenance , AM = AMC Tasks, CA= Calibration ; SD = Shutdown , IN = Inspection (attribute/Value EN-Environment;) J-Jishu Hozen ( General Inspection ) ZX- Safety

Example: GCMGBHPM GCM-GBH-PM 1M Checks

GCEMODPM GCE-Motor-DC-PM 3M Checks

TASK LIST CODIFICATION


Set of Predefined Prefixed Time Intervals ( Called Packages) grouped

at Which Preventive Maintenance Activities can be taken Up.

These Maintenance Strategies can be selected By User to carry out Maintenance Activities depending Upon :--

Age of Equipment Design of Equipment Importance of Equipment in Production Process Maintenance Practices of Organization.

MAINTENANCE STRATEGY


GILDAY -- Frequencies Specified in “ GILDAY”

Are 1W / 2W / 1M / 3M / 6M / 1Y

GILMON-- Frequencies Specified in “ GILMON”

Are 6M/ 1Y/ 2Y/ 5Y

MINEHR -- Frequencies Specified in “ MINEHR”

Are 100HR/ 300HR / 350HR/ 400HR

PERFHR -- Frequencies Specified in “ PERFHR”

Are150HR / 250HR / 500HR/ 1000H

MAINTENANCE STRATEGIES Continued..


GILDAY: Strategy is Used for Frequencies of Check Up to 6M.

GILMON: Strategy is Used for Frequencies of Checks More than 6M.

MINEHR: Strategy is Used For MINES Preventive Maintenance Planning.

PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance

Planning.

APPLICATION: Continued..


MAINTENANCE PACKAGEStrategy GILDAY

Cycle Length UOM Maintenance Cycle Text Cycle Short Text

7 DAY Weekly (1 Week ) 1W

14 DAY Fortnightly (2 Weeks ) 2W

28 DAY Monthly ( 4 Weeks ) 1M

84 DAY Quarterly ( 12 Weeks ) 3M

168 DAY Half yearly ( 24 Weeks ) 6M

336 DAY Yearly ( 48 Weeks ) 1Y

Strategy GILMON


6 MON Half yearly 6M

12 MON Yearly 1Y

24 MON 2 Yearly 2Y

48 MON 5 Yearly 5Y


Strategy MINEHR


96 HR 100 Running Hours ( 96 Hrs) P1




504 HR 500 Running Hours ( 504Hrs) P5

1008 HR 1000 Running Hours (1008 Hrs) P6




3000 HR 3000 Running Hours ( 3000 Hrs) 1P

MAINTENANCE PACKAGEContinued..


Strategy PERFHR


144 HR 150 Running Hours ( 144 Hrs.) P1







12096 HR 12000 Running Hours (12096 H) P8

16128 HR 16000 Running Hours ( 16128 H P9

24192 HR 24000 Running Hours ( 24192 H 1P

32256 HR 32000 Running Hours ( 32256 H 2P

Continued..MAINTENANCE PACKAGE


Display Task List-[IA07] List Editing Task List-[IA09]

DISPLAY CONTENT: Find Task Lists in your Planner group.



MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF MAINTENANCE ITEM MASTER

Equipment /Function Location

Master

Task list Master

Strategy


Maintenance Item describe Preventive Maintenance Tasks

to be performed on an Equipment at Predefined Interval

Maintenance Item = Equipment + Task List with set of operations

with Maintenance Package

MAINTENANCE ITEM


MAINTENANCE MASTERS

BASIC MASTERS


2. Equipment Master


4. MIC’s

5. Work Center

6. Measuring Point

7. Task List Master

8. Maintenance Item

9. Maintenance Plan

BASIC CONTENTS OF MAINTENANCE PLAN MASTER

Maintenance Item Master

Strategy

Scheduling parameter


Maintenance Plan is the Scheduling of Task List attached to an

Equipment (Maintenance Item ) on Time Scale ( According to

Factory Calendar ) or Performance scale ( According to Counter

i.e. Number of Hours).

Plan = Maintenance Item + Scheduling Parameters

MAINTENANCE PLAN


TOLERENCE: ( 50% )

It is the difference between planned date and TECO date ,given in %age for deciding whether maintenance cycle should be shifted or not, considering the gap between planned date and TECO date.

Shift factor” will be effective only if difference between planned date and TECO date is more than 50% of smallest interval (smallest package) , either + or – side. If difference between planned date and TECO date is less than 50% of smallest interval (smallest package) , there will be no shift. For GILDAY , it will be + / - 3.5 days , as minimum frequency is 1w. For GILMON it will be +/- 3 months as min freq is 6M.

SHIFT: 100% .

If condition given in “Tolerance” is true it will shift the maintenance cycle by : given shift % x difference between planned date and TECO date .i.e. Actual delay

MAINTENANCE SCHEDULING PARAMETER


It indicates that an advance intimation of planned maintenance will be given by 0.5 x minimum frequency of strategy selected through order generation .

FOR GILDAY :

1W Being minimum frequency , you will get weekly order 3.5 days

in advance if call horizon is 50%.

CALL HORIZON 50%

MAINTENANCE SCHEDULING PARAMETERContinued..


II. MANAGING MAINTENANCE PROCESSES


MAINTENANCE PROCESSES

BASIC PROCESSES

1. Preventive Maintenance

2. Break down Maintenance

3. Shut down Maintenance

4. Condition base Maintenance

5. Work shop Repair

6. External Repair/Services

7. Calibration

BASIC STEPS OF MAINTENANCE PROCESSES

• Creation of Notification• Creation of Orders• Execution of Orders• Confirmation of Orders• Technical Confirmation of

Orders• Creation of Purchase Request• Creation of Purchase Orders• Service Entry Sheets• Creation of Measuring Points

& Measuring Documents• Installation / De-installation of

Equipments


1. PREVENTIVE MAINTENANCE PROCESS

BASIC PROCESSES





5. Work shop Repair


7. Calibration

BASIC STEPS OF PREVENTIVE MAINTENANCE PROCESS

• Selection of Orders

• Execution of Orders

• Confirmation of Orders

• Technical Completion of

Orders







• Technical Completion of Orders

Selection of Order

Go to T. Code - IW39

Flag Outstanding & In process check box

Enter Order Type PM01

Enter Maintenance Plant

Enter Planner group for Order

Execute by clicking button

Order list of relevant section Appears

Enter Period ( Date from…..to ……)

Enter Status exclusive in Multiple Selection

Select from Drill Down

CRTD, CNF ,TECO & CLSD


H/L TO ORDER TYPES


ORDER TYPES

PM01 --- PREVENTIVE MAINTENANCE ORDERS

• These Orders are Planned by SAP System

• User can not generate PM Work Order for this Order Type externally.

• This Order type will help User to find out Cost of Preventive Maintenance exclusively for his Plant section/Planner group.

• User will be able to compare Cost Of Preventive Maintenance vis-à-vis Breakdown and Shutdown Maintenance.

• User will be able to judge the effectiveness of Preventive Maintenance Plans by this Order Type.

• Order Numbering is blocked for this Order

• User will get Preventive Maintenance Orders under Maintenance Activity Type - PVM , Annual Maintenance Contract Orders under Maintenance Activity Type - AMC and Inspection Orders under Maintenance Activity Type INW


PM02: BREAKDOWN MAINTENANCE ORDERS

•This Order Type is exclusively for Breakdown registration of Equipments

•This Order Type indicates Unplanned stoppage in Production Process

• In addition to consumption of Recourses like Men , Machine , Material , Production loss is also associated with this type of Order .

• User can further segregate the breakdowns of Equipments under Warranty / Insurance from other Breakdowns.

PM03: SHUTDOWN MAINTENANCE ORDERSThis Order Type indicates • Annual Shutdowns ( Maintenance Activity Type: SDM)

• Planned Weekly,Fortnightly,Monthly Stoppages ( Maintenance Act. Type : WFM)

• Opportunity Based Maintenance (Maintenance Activity Type: OPP)The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be booked under MAT- SDM.

Continued..ORDER TYPES


PM03: SHUTDOWN MAINTENANCE ORDERS

• Only Planned Weekly,Fortnightly,Monthly Stoppages will be booked under Maintenance Activity Type – WFM• Other Maintenance jobs not planned but undertaken because of availability of Opportunity are booked under MAT-OPP.

PM05: CALIBRATION MAINTENANCE ORDERS

• This Order Type is applicable for Calibration of Equipments• These Orders are Planned by System . However , User can also raise Order externally , if required for unplanned Calibration jobs.• This Order Type has MAT- CAL .

PM06 : CORRECTIVE MAINTENANCE ORDERS

• The jobs covered under this Order Type are of 2 types: Corrective Actions suggested under WHY-WHY Analysis to avoid recurrence of Breakdown will be covered under Maintenance Type – WHY .



PM06 : CORRECTIVE MAINTENANCE ORDERS• Other Maintenance Jobs of Corrective Nature e.g. Maintenance Requests from other departments , Removal of Abnormalities/Defects, Removal of Unsafe Conditions where Breakdown has not occurred will be covered under MAT- CRM

PM07 --- CONDITION BASED MAINTENANCE ORDERS• This Order Type is applicable for jobs planned on the basis of Condition of Spares. E.g. Replacement of Worn Out Chain/ Worn-out Hammers etc

• MID , being Condition Monitoring Department , will use this Order Type for advising repair /

replacements on the basis of Condition E.g. Hardness/Thickness/Vibrations etc

PM08 --- GENERAL MAINTENANCE ORDERS• This Order Type is applicable for UNDEFINED jobs NOT FALLING under above categories and not related to Equipment. E.g. Leakage of Water Tap in Administration Building garden.• These are of Minor nature Repair Jobs.

•This Order Type should not be used unless it satisfies above condition



PM09: REPAIR MAINTENANCE ORDERS

There are Four different Activity Types or jobs covered under this category. They are:

• Work Shop jobs should be registered under MAT – RWS• Rewinding jobs should be registered under MAT - REW• Tyre Retreading jobs should be registered under MAT – RET• External Repair jobs should be registered under MAT – RVN

PM10: IMPROVEMENT/MODIFICATION ORDERS

• All jobs of Improvements and Modifications in Maintenance (Reliability MTTR/MTBF/Maintainability/Availability) are covered under Maintenance Activity Type – IMO

• Suggestions given by Consultants/Experts/Other Units/ Other sources like Websites, Manuals, Magazines etc are covered under Maintenance Activity Type – CON.

PM11: CAPEX/BLOCK ORDERS

• All Work Orders raised for Project Work are covered under this Order Type and MAT-CAP

PM12 --- CIVIL MAINTENANCE ORDERS

• All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/ Foundation etc are covered under this Order Type and MAT-CIV



Order Type Description Order Activity Type

PM01 Preventive Maintenance Order PVM,AMC,INW

PM02 Breakdown Maintenance Order BDM,WAR,INS

PM03 Shutdown Maintenance Order SDM,OPP,WFM

PM05 Calibration Order CAL

PM06 Corrective Maintenance Order CRM,WHY

PM07 Condition Based Maintenance CBM

PM08 General Maint Order GEN

PM09 Repairs Order RWS,RVN,RET,REW

PM10 Improvement/Modification Order IMO.CON

PM11 Capex / Block order CAP

PM12 Civil Maintenance Order CIV

QCAL QC Insp./ Calibration Order CAL

MAINTENANCE ACTIVITY TYPES IN PM ORDERS








Selection of Order


Flag Outstanding & In process check box






Enter Period ( Date from…..to ……)



CRTD, CNF ,TECO & CLSD


H/L TO ORDER TYPES



BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of Orders

Move to SAP Screen

Select desired order




Go to Operation TAB and Change operations etc if reqd

Select operation & Go to Component TAB if Material Required

Select required Component

Enter reqd Qty , Item category, Storage Location & Batch

Enter number of Selected Order


Release PM01 Type Selected Order

Order status will be changed to REL from CRTD

Execution of Orders

Enter Start Date & Time

Come to Header data Tab




End date & time will be changed by system

Determine cost by clicking

Save the Order

Move to SAP Screen

Schedule Order by Clicking








Confirmation of Order

Go to T. Code – IW44

Select Header Menu Confirmation

Select “via operation list” in Confirmation Menu

Enter Order type

Enter Planner group


Selection of operation list appears

Enter Plant

Enter Status Exclusive in Multi Selection List

CRTD, CNF , TECO & CLSD

Enter Reference date




All Planning data of operations defaulted from relevant Orders

Flag Final confirmation, Clear all Res & No remaining work

Enter Start Date & Time

Enter End Date & Time

Select All Operations

Click All Actual Data on Header Tool bar

All relevant Orders with Operations will be copied on main screen

Enter Actual Work Center Qty





Enter Confirmation Text

System will calculate Actual Duration

Save Confirmation by clicking

Move to SAP Screen

Enter Actual Duration



BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Completion of

Orders

CRTD, REL , TECO & CLSD


Technical Completion of Order


Flag In process check box



Enter Period (Date from…to…)


Selection of Order Screen appeared





BASIC STEPS OF MAINTENANCE PROCESSES• Selection of Orders• Execution of Orders• Confirmation of Orders• Technical Confirmation of

Orders Click Settlement Rule button

Click Flag of Technical Completion

Enter / change cost center & give % if required

Order Main Header Screen Opens


Select order and click

Enter Reference Date & Time

Click Enter Button

Order is Technically Completed & System Status Changed to TECO

Move to SAP Screen


2. BREAKDOWN MAINTENANCE PROCESS

BASIC PROCESSES





5. Work shop Repair


7. Calibration

BASIC STEPS OF BREAKDOWNMAINTENANCE PROCESS

• Creation of M2-Notification

• Selection of M2-Notification

• Creation of PM02-Order

• Selection of Order




• Execution & Completion of

Notification

• Why-Why Analysis












Notification


Enter Notification Type

Do not Enter Notification Number

Go to T. Code – IW21Create Notification

Enter Notification Description

Enter Equipment / FL / Assembly (as required)

Enter Reported By (Name)

Creation of M2 Notification

H/L TO N/F Types

System Generated

Notification Tab Screen Appears

Manual Process


Click Enter Button


M1 --- MAINTENANCE REQUEST

This Notification type indicates a request made by Customer department to his Supplier/Service Provider. E.g Request made by Raw Mill Mechanical for repair of Gear Box shaft on Workshop.

This includes all types of jobs of Maintenance/Repair/Service requests made by User on Service Provider EXCEPT Malfunction/Breakdown.

M2 --- MALFUNCTION/BREAKDOWN

This Notification Type is exclusively for information regarding Breakdown of EquipmentsThis Notification is raised generally by Production on relevant Maintenance Department as a FIR of Unplanned stoppage in Production Process.However , anybody can raise this Notification if it satisfies above condition.

NOTIFICATION TYPESContinued..


M3 --- UNSAFE CONDITION/ACCIDENT

• This Notification is an information from any department including Safety regarding prevailing Unsafe/ Hazardous Condition which is dangerous and may cause damage to Property/Human being / Environment /Surroundings etc , to the relevant department responsible for such condition for necessary corrective action.

M4 --- ABNORMALITY RECORD

• This notification is raised to register 7 types of Basic Defects in Equipments. These defects are revealed through Daily Check List/ Inspection/Plant Round Satisfies the WCM requirement to monitor 7 type of basic defects which are responsible for Breakdown , if not corrected in time.

NOTIFICATION TYPESContinued..


M5: RECOMMENDATION/IMPROVEMENT

•This Notification is generated by User for any improvement/development to be implemented .• The source for Improvement/Modification/Development in Reliability/ Availability /Maintainability may be WHY-WHY Analysis, Experts/Consultants recommendation/Other Units/KIP’s etc• The number of such Notifications will be an indicator of improvements done by User • These notifications will give List of Improvements done by User which is required by WCM or for sharing with other Units.

M6 --- WORK REQUEST-WORKSHOP

• This notification is raised by User on workshop requesting its services for Repair/Machining/Replacement of Spares/Assembly/Equipment etc.

Continued..NOTIFICATION TYPES


M7: GENERAL NOTIFICATION.

•Notification which does not fall in any of the conditions mentioned above may be raised in this type.•This type of Notification should not be used as far as possible as it will affect history/vital information about Equipments.

M8: MEASURING POINT ERROR

•This notification is raised by the SAP system automatically whenever the Parameter defined as a Measuring Point deviates from its Standard Value or goes beyond its Acceptable Permissible Value.

Continued..NOTIFICATION TYPES


Notification Types

Notification Type Description Number Ranges From -ToM1 Maintenance Request 1000000000 to 1999999999M2 Malfunction, B/Down 2000000000 to 2999999999M3 UnsafeCond./Accident 3000000000 to 3999999999M4 Abnormality Record 4000000000 to 4999999999M5 Recommendation 5000000000 to 5999999999M6 Work Request- W.Shop 6000000000 to 6999999999












Notification









H/L TO N/F Types

System Generated


Manual Process


Click Enter Button



All information Defaulted from equipment master










Notification


Go To Location Data Tab

Release & Save the Notification

If Reqd Enter Long Text

Flag breakdown check box

Main Work center/ Planner Group etc Defaulted & can be Changed If Required

Naviaget >SAP Screen

In case of Main Plant, M2 Type Notifications will be Generated by System thru breakdown entry made by CCR

Enter Code of STD TEXT Attached

Popup Massage of warranty Prompts

If equipment Under warranty













Notification


Flag check box Outstanding or In process (as Reqd)

Enter Notification Date

Go to T. Code – IW28 Selection of Notification

List of Notifications Appears as per Selection Criteria

Select relevant Notification

Selection of M2 Notification


Enter Planner group

Click Enter Button

Click on Details Button

Navigate. SAP Screen

Notification Change Screen Appears













Notification


M2 Notification selected in Changed Mode as explained in pervious sheet

Further process of order will remain same as explained in process “1. Preventive Maintenance”

Enter PMActType BDM & click continue button & save

Create Order Popup Screen Appears with Defaulted data from notification

Creation of PM02 Type Order from Notification

Click Create button

of Order Tab

Breakdown Order Created

Navigate> SAP Screen



Process of Selection of Order, Execution of Order, confirmation& TECO will be similar to processes explained in process “1. Preventive Maintenance”










Notification













Notification


M2 Notification selected in Changed Mode as explained in pervious Process

Next Popup screen Database selection for SAP script text

On Insert Text screen Flag Expand immediately , enter Text ID – ST & click on dropdown of Text Name field

Insert Text popup screen appears.

Execution of M2 Notification (Order not generated)

To Attach Std Text Go to Effect field & select relevant code of Std Text



Execute Popup screen Database selection for SAP script text without entering any data












Notification


Select malfunction& downtime tab and Enter down time end Date &Time.

Desired Standard Text Get copied in long text. Complete it & go back to main screen

Now popup screen Insert Text appear again with text attached. Click Continue Button

Next Popup screen Find SAP script text will appear. Select relevant text & click continue button



Click Complete Flag and complete Notification












Notification


Select status by flagging and execute

Enter Date Range (From...To…)

Go to T. Code -- ZRPM-WHY

Create Why Why Analysis Sheet

Enter Plant , Plant Section & Planner group

List of Notification appears (as per selection criteria)

Select relevant notification & double click it

Why Why Analysis screen Appears













Notification


Enter Observations

Flag YES box to actual Cause

Enter Object Code

Enter all Possible Causes (Possible reasons)

Enter Analysis In Why Why Field

Enter Rectification carried out

Enter Recommendations

Enter Damage Code

Enter Responsible person and Tar Date for Recommendations

Select Document Attached - Say 2















Notification



Change Why Why Analysis

Next procedure of Standard text shall be similar as explained in Process “ Execution of M2 Notification”

Click Complete Flag and Complete Notification

Save why-why Analysis

Go to Main screen of selected Notification’s why why analysis

Click “Put in Process” Flag

Change Why Why analysis data as per requirement

Save changed why-why Analysis

Go to T. Code – ZRPM_WHY


3. SHUTDOWN MAINTENANCE PROCESS

BASIC PROCESSES





5. Work shop Repair


7. Calibration

BASIC STEPS OF SHUTDOWNMAINTENANCE PROCESS

• Creation of PM03 - Shutdown

Orders

• Selection of PM03 - Shutdown

Orders

• Report of Shutdown Planning

• Creation of Direct Purchase

Order


Request (Indent)






Enter Equipment Number

Equipment selection screen appears

Equipment Category - M

Enter plant Section

Enter Planner Group

Enter Order Type - PM03

Go to T. Code – IW31



Orders


Orders



Order


Request (Indent)





Creation of Shutdown Order

Enter Equipment Class (Optional)

Maintenance Plant

Click Execute Button


By Drill Down go to selection screen










Orders


Orders



Order


Request (Indent)




Enter Order Description

Go to Header data Tab & Enter PMActTYPE - SDM

Enter Relevant Work Center

Select Desired Equipment & click . Equipment entered in

field

Go to Operation Tab and Enter Operations as required

Enter Relevant Control key

Enter Planning Plant & Enter

Create Shutdown Maintenance Order : Central Header Screen appears

Pl Refer Next Slide

Better to Create Separate Order for PMIN & PMEX Control key




Enter Cost Element & Press Enter

Popup screen External Processing Operation appears

Select Material Group ( S524 For External Services) & Pur. Group

Go to service tab & Select Desired Services from Service Master or write Description only & Enter Required Quantity

Select Operations

Activity type Defaulted

Select Operation & Go to Component TAB if Material Required

Enter WC Qty and Cal.Key

Enter Work or Duration

After Assigning Control Keys PMIN PMEX

Enter required Material, qty, S.Loc (see stock) & Batch

Click Gen Data Button & Get Reservation Number on comp detail screen & come back

Click on External Button

External Processing operation Appears

Enter Vender , tracking No & click


Again Go to Operation screen Enhancement Button and enter Field key – ZPM0001, Position






For Release Order Press Icon

Save Order by click button

Click scheduling & determine cost button


Create Purchase Requisition screen appears. Enter Dept and Press Enter

Enter Cost Element & Press Enter

Repeat above three steps for Next Operation's

Go to Header Screen & Click Determine cost button

For Release Order Press Icon

Save order by click button

You can See PR No Thru GEN data->Act data Tab






Orders

• Selection of PM03 -

Shutdown Orders



Order


Request (Indent)




• Technical Completion of

Orders

Process of Selection of Order, Execution of Order, confirmation & TECO will be similar to processes explained in process “1. Preventive Maintenance”





Orders


Orders



Order


Request (Indent)




Enter Order type

Enter Main work center

Enter Plant Section

Enter Planner Group

Flag Outstanding & In process Order

Go to T. Code – IW49N

Report1. of Shutdown Planning

Maintenance Plant

Display order & Operation: selection of order & Operation screen appears

Enter Period (dates)










Orders


Orders



Order


Request (Indent)





Report of Order with Operation etc Appears

View Reports with Relevant Layout selection





• Creation of PM03 -Shutdown

Orders

• Selection of PM03 -Shutdown

Orders



Order


Request (Indent)




Flag outstanding & In process

Click Multiple Selection of Order Field

Enter Plant Section

Material availability Information screen

Go to IWBK – Material Availability Check (for orders)

Report 2 of Shutdown Planning (MATERIAL)

Maintenance Plant

Enter Period (dates)


Enter Order Type- PM09

Click Multiple selection button



Enter Planner Group Select from Drill Down





Orders


Orders



Order


Request (Indent)




Paste Selected Orders & execute


Screen of “Availability list of Materials for Operations” will appears

You will reach back to main screen of Material availability Information

Go to back to Multiple selection screen & Execute

Click execute button again

Report of Order with Operation etc Appears

On This Screen You Will Get Order wise Materials with Stock Availability status Navigate> SAP Screen





Orders


Orders



Order (For Contractors)


Request (Indent)




Creation of Direct Purchase Order (For Contractors)

Go to T. Code ME21N –Create Purchase Order

Select Type of Purchase Order

Go to item overview Tab and Enter Account Assignment – K and Item category - D

Enter Material Group , Plant , tracking number (Employee) and Department (planner group)

Enter Vendor Code Select from Drop Down thru Vendors : Purchasing

Enter Purchase Organization, Purchase Group & Company Code

Enter Short text of Services

Select from Drop Down



Select from Drop Down. Search Tracking number thru “Vendor by Company code”





Orders


Orders





Request (Indent)




Go to Account Assignment Sub Tab and Enter G/L Account number and Cost center

Correct Entries If error massage other wise Save the order

Check entries by Clicking Button


Go to Item Tab and Enter Services number , Qty




BASIC PROCESSES





5. Work shop Repair


7. Calibration

BASIC STEPS OF SHUTDOWN

MAINTENANCE PROCESS

• Creation of Measuring Point

• Selection of Measuring Point

• Creation of Measuring Document &

Auto Notification

• Creation of Entry List

• Measuring Document Thru Entry list

• Selection of M8 type Notification

• Creation of Corrective Maintenance

Order Thru Notification




4. CONDITION BASE MAINTENANCE PROCESS





Orders


Orders





Request (Indent)




Creation of Direct Purchase Requisition (For Spare)

Go to T. code ME51N -Create PR

Enter PR Type & Header note

Account Assignment Type – U & Item Category leave Blank

Enter Material & Reqd Qty

Enter Del date , Plant & Tracking number (planner group)

Check entries by Clicking Button

Correct Entries If error massage other wise Save the Purchase request








BASIC STEPS OF CONDITIONBASE MAINT. PROCESS



• Creation of Measuring

Document & Auto notification


• Measuring Document Thru

Entry list

• Selection of M8 type

Notification

• Creation of Corrective

Maintenance Order Thru

Notification• Execution of Orders• Confirmation of Orders• Technical Completion of Orders

Select & enter Equipment number

Select Relevant Measuring Point Category (Except L & F)

Do not flag MP as counter for CBM

Select Measuring Point Object - IEQ

Go to T. Code - IK01 -Crete Measuring Point

Creation of Measuring Point

Click on Enter Button

Write Measuring Position & Description










Entry list


Notification




Main screen appears. Now click on Save button to save MP

Enter Upper range limit & Lower range limit



Go to Additional data Button header tool bar

Enter relevant Characteristic (UOM & decimal Place defaulted)










Entry list






Selection of Measuring Point

Measuring point list appears

Select relevant Measuring point

Enter Characteristics & MP Category

Go to T. Code - IK07 – Display measuring Point : Measpoint Selection








Document & Auto Notification



Entry list





Creation of Measuring

Document

Enter MeasRdg as taken from site

A Massage Appears In case Reading is Outside range

Enter Measuring Point (as selected)

Go to T. Code – IK11 - Crete Measuring Document

Again Click on Enter Button

Main screen of M8 type Notification Generates Automatically









Document & Auto Notification



Entry list






A massage comes for Measuring document Created

Enter Reported by & click Enter button

An Auto Notification of M8 type Created










Entry list


Notification




Screen of Measuring reading entry list: Create Appears

Enter entry list name & Description

Enter measuring point numbers As selected from drop down list

All details of Measuring points Appears in list

A Massage “ measurement reading entry list xxx saved.

Go to T. Code – IK31 - Measuring reading entry list: Create

Creation of Entry List



Now Click on Save Button











Entry list


Notification





Enter Entry list number

Collective entry of MeasDocuments: overview screen Appears

Enter measuring Reading in relevant measuring point field

Go to T. Code – IK34 – Collective entry of MeasDocuments: Initial screen

Creation of Measuring Document Thru Entry list



A Massage Appears In case Reading is Outside range &click again enter button. M8 Notification will generate

A massage appears as xx Measuring document Created


5. REPAIR MAINTENANCE PROCESS

BASIC PROCESSES





5. Work shop Repair


7. Calibration

BASIC STEPS OF REPAIR MAINTENANCE PROCESS









Notification




• Creation of M 6-Notification

• Selection of M 6-Notification







Notification








H/L TO N/F Types

System Generated

Enter Code of STD TEXT Attached

Select from Drill Down as per requirement


Manual Process

Click Enter Button













Notification


Go To Location Data Tab

Save the Notification

Write Details of Job in Long Text

Main Work center/ Planner Group etc Defaulted & can be Changed If Required

All information Defaulted from equipment master













Notification

Flag check box Outstanding (as reqd)

Enter Notification Date

Go to T. Code – IW28 Selection of Notification

Select Notification & Create PM09 Type Order

Click Create button

of Order Tab

Selection of M6 Notification













Notification

Select Relevant Work Center (Type 0001)

Enter Number of Hours


Select Relevant Maintenance Activity Type( Always RVN)


Other Field automatically Populated.

Go to Operation TAB


Select Relevant Work Center for Operator & Enter Number of Hours

Go to Component TAB & Attach Required Material

Create PM09 Type Order












Notification

GO to IW38 & Search PM09 Type Order













Notification

Release Order & Issue Required Material.

Carry out Repair Work As per Request













Notification

Further process of order will remain same as explained in process “1. Preventive Maintenance”



6. EXTERNAL REPAIR MAINTENANCE PROCESS

BASIC PROCESSES





5. Work shop Repair


7. Calibration

BASIC STEPS OF EXTERNAL REPAIRMAINTENANCE PROCESS

• Creation of PM09 Type Order

• Selection PMEX Activity type

• Creation of Purchase

Requisition

• Creation Of Purchase Order

• Confirmation of External

Service Entry Sheet




BASIC STEPS OF EXTERNAL REPAIR PROCESSES



• Creation of Purchase Requisition

Creation of Purchase Order

• Confirmation of External Service Entry Sheet


Select Relevant Type Maintenance Activity (Always RVN, RWN)


Select Control Key As PMEX

Go to Operation TAB

Click External Service Button

Creation of PM09 Type Repair Order

Enter Operation & Select It

POP Screen Will Appear Enter Material Group S 524,Purchase Group, Tracking Number

Enter & GO to External Processing operation Screen





• Creation of PM09 Type Order• Selection PMEX Activity type• Creation of Purchase

Requisition• Creation of Purchase Order• Confirmation of External Service

Entry Sheet• Technical Completion of Orders

Write Short Text of External Service , Approximate Cost of Repair, Quantity & Unit

Enter Cost Element & click

Pop Screen of Purchase request Will Appear Enter Department (i.e Main Planner group)

Go back to Order main screen Release it & Save Order

Go to Change Mode of Order & select TAB Actual Data You will get PR number

Write Desired Vendor Code







• Creation of PM09 Type Order Selection PMEX Activity type• Creation of Purchase

Requisition• Creation of Purchase Order• Confirmation of External

Service Entry Sheet• Technical Completion of

Orders

GO TO Customer TAB & Enter all Required Deatils

Go To Change Mode of PR (ME52N)

GO To Document Overview & Select Relevant PR

Save PR




MM Will Prepare Purchase Order on PR





• Creation of Purchase Order





MM Will Prepare Service Entry Sheet You will Accept Service Entry Sheet










This Type of Order to be TECO only When FINAL Service Sheet Made.








Save


III. MANAGING REPORTS


STANDARD REPORTS

1. Object Class Statistics [MCI1]

Object breakdown analysis in terms of Maintenance cost

Standard drill down (Key Figure)

Assembly Construction yearManufacturer Material Object class

Month


2. Manufacturer Analysis [MCI2]

Object breakdown analysis in terms of Maintenance costManufacturer wise.

Standard drill down (Key Figure) Assembly Construction yearManufacturer Material Object class Month

STANDARD REPORTS


3. Location Analysis [MCI3]

Object breakdown analysis in terms of Maintenance cost Location wise

Standard drill down (Key Figure) AssemblyEquipmentFunctional LocationLocationMaintenance plantPlanner groupPlanning plantPlant sectionMonth

STANDARD REPORTS


4. Planner Group Analysis [MCI4] Object breakdown analysis in terms of Maintenance cost

Planner Group wise

Standard drill down (Key Figure) AssemblyEquipmentFunctional LocationLocationMaintenance plantPlanner groupPlanning plantPlant sectionMonth

STANDARD REPORTS


5. Single Object - Damage Analysis [MCI5]

Object Damage analysis in terms of Damage & Causes, Notification Type wise

Standard drill down (Key Figure)Activity codeCause of damageCdGrp: damage causeCode group: activityCode group: damageDamageEquipmentFunctional LocationNotification typeMonth

STANDARD REPORTS


6. Object Statistics [MCI6]

This report provide the detail about the object statistics ( like how many Equipment installed on a Function Location)


Object classManufacturer Material Construction yearMonth

STANDARD REPORTS


7. Breakdown Analysis [MCI7]

This report provide the Breakdown Analysis information(No. of B/D, MTTR, MTBR etc.).


EquipmentFunctional LocationObject classMonth

STANDARD REPORTS


8. Cost Analysis [MCI8]

This report provide the Breakdown Analysis information( No. of B/D, MTTR, MTBR etc.).


EquipmentFunctional LocationObject classMonth

STANDARD REPORTS


9. MTTR/MTBR Equipment [MCJB]

This report provide :

MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR etc.).

Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)

STANDARD REPORTS


10. MTTR/MTBR Functional Location [MCJC]

This report provide :

MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR etc.)

Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)

STANDARD REPORTS


6.2 LIST OF DEVELOPED REPORTS


The following are the Reports that are being developed in SAP:

LIST OF DEVELOPED REPORTS:

S. No. PLANT REPORTS

1 List of Damage & Cause - Summary Report (Equipment wise)

2 Breakdown Matrix - Equipment ABC indicator & breakdown category wise

3 Work Center / Equipment wise Material Consumption

4 Equipment Schedule Maintenance Report

5 Breakdown why-why Analysis Report

6 PM order Skipped / Rescheduled Report

7 PM Order Slippage Summary Report ( Schedule Maintenance Slippage in Plant VC)

8 Preventive Maintenance Work Request Report

9 Motor Failure Report

10 Inspection Check List


S. No. PLANT REPORTS

11 Maintenance Order / Operation Pending List

12 Section / Equipment Performance Report

13 Equipment Lubrication Consumption Report

14 Quarterly Lubrication Consumption Report

15 Purchase Request Tracking Report

16 Equipment Maintenance Cost Report

17 List of Service Entry Sheets

18 Work Center Wise Service Cost Report

19 Shutdown (consolidated) Planning Report (resources & cost)



S.No. MINES REPORTS

20 Tyre Life Summary Report

21 Equipment Position Wise Tyre Run Report

22 Tyre Maintenance Register

23 Oil Consumption Report

24 Oil, Filter & Lubricant Monitoring Report

25 Assembly Life Details

26 Sub assembly Performance Report

27 Breakdown Summary



Select Equipment

Select Relevant Measuring Point Category

Flag for Measuring Point as a Counter

Write Measuring Position Description

Write Description of Measuring Point

Measuring Point Object

Attach Relevant CHARACTERISTICS

Crete Measuring Point- IK01

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1




Select From Drop Down ,Always use RUNNINGHOURS


Enter Annual Estimate Reading

Press ICON For Save

Message : “Measuring Point ………. Created

Enter Counter Over Flow Reading

Press Enter ICON

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2

Maximum Reading of Counter

It Will be drive Plan

THE END


Select Equipment


Flag for Measuring Point as a Counter






CREATION OF MESURING POINT (LUB/Diesel Consumption) Sheet 1/2



Always Select Category L- for Lubrication & F- Fuel Consumption

Select From Drop Down , ,Always LUB CONCOSUMPTION…..


Enter Save ICON Button

Message : “ Measuring Point ……..Created

Don’t Enter Counter Over Flow Reading & Annual Estimate Reading

Press Enter ICON

CREATION OF MESURING POINT(LUB/Diesel Consumption) Sheet 2/2


Message : “ Measuring Point ……..Created The END


Press ICON


Select Equipment


Press Icon






CREATION OF MESURING POINT Sheet 1/2




Select From Drop Down



Message : “ Measuring Point ……..Created


Press Enter ICON

CREATION OF MESURING POINT Sheet 2/2


Message : “ Measuring Point ……..Created THE END


Press ICON


Enter ICON Button Next Screen will Appear for entering Reading

Enter Counter Reading or Difference of Counter

Select Desired Measuring Point

Creation of Measuring Document IK11

CREATION OF MESURING POINT DOCUMENT (IK11)

Press ICON Button For Save


Counter should be GREATER than Previous Reading or Difference not more than 24 Hours

Message : “Measuring Document ……..Created.

THE END


WITH

TIME BASED PACKAGE

Continued..MAINTENANCE ITEM



Write Maintenance Item Description

Enter Equipment

Write ORDER Type

Maintenance Activity Type

Maintenance Plan Category

Attach Relevant Task List

Create Maintenance Item IP04

CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04


This will be PM01 Always

Select from Drop Down (Use PVM Or AMC )


Select from Drop Down, Use Always GILDAY & GILMON Only


Flag General Task List

Press Icon , Screen will appear with List of Task Lists

Select Appropriate Task List

Press Icon Enter

Press Icon for Save

Task List Display Screen will Appear on Screen

You will get Message : Maintenance Item ( System Generated Number) Created. THE END

For Selection of Task List Use Icon

CREATEING MAINTENANCE ITEM (TIME BASE) Sheet -2/2


WITH

PERFORMANCE BASED PACKAGE

MAINTENANCE ITEM



Write Maintenance Item Description

Enter Equipment

Write ORDER Type

Maintenance Activity Type

Maintenance Plan Category

Attach Relevant Task List

Create Maintenance Item IP04

CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2


This will be PM01 Always



ALWAYS Use PERFHR –For Plant,TPP,DG Equipment & MINHR – For Mines Equipment


Flag General Task List

Press Button , Screen will appear with Task List

Select Appropriate Task List

Press Icon

Press Icon for Save

Task List Display Screen will Appear on Screen

You will get Message : Maintenance Item ( System Generated Number) Created THE END

For Selection of Task List Use Button

CREATE MAINTENANCE ITEM (PERFORMANCE BASE )Sheet -2/2


Creation of Maintenance Item-[IP04]



Maintenance Category


Press Icon

Write Maintenance Plan Short Description

Go to TAB For Assigning Maintenance Item

Maintenance Plan Number is System Generated Number

POP Screen will appear Message : Possible Deletion of Data Entered When Selecting

Create Maintenance Plan (IP01)

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3 IP01

Select from Drop Down ,Always Use GILDAY & GILMON


Main Planner Group ,Main Work Center & other field automatically Populated

Main Planner Group ,Main Work Center & other field automatically Populated from Equipment Master

Press Icon

Go to TAB “Maintenance Plan Scheduling Parameter

Write Scheduling Period :365 Days


Flag Fro Completion Requirement

Display Maintenance Item :Selection Criteria Screen Will Appear ,Write Equipment Number & Press Icon

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 2/3


Select Radio Button “NO”

Press Icon

Message will Appear on Screen :” Maintenance Plan ……….Created

The End

Pop Screen Will Appear For START DATE

Press Icon For Save

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 3/3


Maintenance Category


Press Icon

Write Maintenance Plan Short Description & Enter Counter

Go to TAB For Assigning Maintenance Item

Maintenance Plan Number is System Generated Number

POP Screen will appear Message : Possible Deletion of Data Entered When Selecting

Create Maintenance Plan (IP01)

CREATION OF MAINTENANCE PLAN (PERFORMANCE BASE) Sheet 1/3

Select from Drop Down ,Always Select PERFHR –For Plant, DG, TPP & MINHR – For Mines


Main Planner Group ,Main Work Center & other field automatically Populated


Press Icon

Go to TAB “Maintenance Plan Scheduling Parameter

Write Scheduling Period :365 Days


Flag For Completion Requirement

Display Maintenance Item :Selection Criteria Screen Will Appear ,Write Equipment Number & Press Icon

CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 2/3


Select Radio Button “NO”

Press Icon

Message will Appear on Screen :” Maintenance Plan ……….Created

The End

Pop Screen Will Appear For START Counter Reading

Press Icon For Save

CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 3/3

61114169 sap pm training

Documents

preventive maintenance navigate

click button navigate

relevant section appearsselect

field automatically populated

group pm proc

group pm mech

group pm mine

annual estimate reading