alm function in details

Functions in Detail

SAP® Asset Lifecycle ManagementMaintenance made easy

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Contents

SAP® Asset Lifecycle ManagementAsset Lifecycle Management with SAP 1-1

Asset Lifecycle Management Today 1-1Asset Lifecycle Management with SAP PM 1-3Optimizing Your Processes 1-6

Example Assets 2-1Example 1: Individual Object (Automobile) 2-3Example 2: Complex Technical System (Power Station) 2-4Example 3: Inventory-Managed Objects (Hardware) 2-6Example 4: Real Estate Management (Building) 2-8Example 5: Classification of Objects (Electric Pumps) 2-9Example 6: Integration of External Systems

(GIS and Power Supplies) 2-11

Processes in Asset Lifecycle Management 3-1Breakdown Maintenance 3-3Corrective Maintenance 3-4Inspection and Preventive Maintenance 3-12Executing and Monitoring Preventive Maintenance Work 3-15Work Clearance Management 3-18Exchanging and Refurbishing Repairable Spares 3-21Managing External Resources 3-23Projects 3-25

Analyses for Asset Lifecycle Management 4-1Information at Every Level of Detail 4-1The Right Tool for Each Employee 4-4

Integration and Interfaces 5-1Integration in mySAP.com 5-1General System Functions 5-2Integration with External Systems 5-3

Range of Functions 6-1

Glossary G-1

Index I-1

Note to Readers

Who is the brochure intended for?

This Functions in Detail brochure describes the processes and functions availablefor asset lifecycle management using SAP PM. It is targeted at those managersand employees responsible for choosing and implementing software.

How is the brochure structured?

In the first unit, we provide you with a brief overview of SAP PM and highlighthow you can optimize processes in your company.

Numerous examples in the second unit serve to illustrate the many uses of SAP PMfor managing technical objects.

The third unit describes the most important business processes for asset lifecyclemanagement in detail, including breakdown maintenance, inspection andpreventive maintenance.

In unit four, we present analyses for your different users.

Unit five deals with the integration of SAP PM with other SAP components andexternal systems.

Finally, unit six presents an overview of the wide range of functions that weprovide.

What terms do we use?

Within the world of asset lifecycle management, companies often use manydifferent words to describe the way in which they work, and indeed, can eveninterpret the same word differently. For example, the terms �notification� and�order� may have different meanings in different companies.

In the SAP System, we place great value on consistent terminology. It may bethat you are unfamiliar with one term or another in the brochure, but we believethat these �SAP terms� lead to a greater understanding of the business processesin SAP PM and can be assimilated quickly and easily into your everyday use.

A glossary of the terms used in SAP PM can be found at the end of this brochure.

What is ALM?

ALM stands for Asset Lifecycle Management and consists of two products:internal Plant Maintenance (SAP PM) and external Customer Service (SAP CS).This brochure deals exclusively with the SAP PM product.

Asset Lifecycle Management with SAP

1-1


Highlights

Are you looking for a reliable, flexible, long-term software solution for your assetlifecycle management? A solution that focuses on people without forfeitingfunctionality? A system you can use internationally? A tool that represents yourindividual organizational structure and high-value assets exactly as you choose?

Then look no further. SAP PM has everything that you need for asset lifecyclemanagement and much more. With SAP PM, you can integrate your assetlifecycle management with all the other enterprise areas. We ensure you stay ontop of your work. We understand the needs of asset lifecycle management becausewe talk to the people who work there. Reap the benefits of our experience andinvest in a solution with a future: SAP PM.

Asset Lifecycle Management TodayKeeping Track of Your LifecyclesAsset Lifecycle Management forms part of mySAP Product Lifecycle Management

(PLM). mySAP PLM creates a collaborative environment for managing thecomplete product and asset lifecycle through a quality-driven, extended supplychain.

E-Business in Asset Lifecycle

Management

For product development-driven environments, mySAP PLM provides acomplete solution to manage all product-related business processes � from thefirst idea onwards, through design and production to obsolescence. It extendstraditional PLM capabilities by providing a unique e-business solution thatenables collaborative engineering, customer product development, and programmanagement among multiple business partners.

SAP PM provides functions for asset lifecycle management. Its assetmanagement capabilities target project managers and maintenance engineersto assist them with all kinds of physical assets and equipment, from the firstinvestment idea, through the start of operation to the end of operation andreplacement of assets. The solution covers all components of a fully integratedComputerized Maintenance Management System (CMMS), including integratede-procurement to order supplies for maintenance, inventory management andshutdown planning.


1-2

Fig. 1-1: Management of Product and Asset Lifecycles

mySAP PLM uses state-of-the-art technology for all types of communication.In addition to the standard Internet services, communication via pagers, mobileand hand-held devices is also supported.

mySAP PLM is closely linked with other mySAP.com solutions. It is deliveredthrough the mySAP Workplace and is also integrated with mySAP SCM,mySAP CRM, mySAP E-Commerce, mySAP Business Intelligence and mySAPMarketplace to support collaborative engineering design and procurement.

Fig. 1-2: From Product Idea to Asset Obsolescence

Efficient Asset Lifecycle Management: A

Strategic Advantage

The question of asset lifecycle management has never been more important thanin today�s world of globalization. Companies must maximize every conceivableadvantage to keep pace with the competition. To regard efficient maintenancemerely as an unavoidable cost is to neglect one of the most important strategicopportunities available.


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Asset Lifecycle Management with SAP PM

Focusing on the PeopleSAP PM puts the focus firmly back on the people. Only a software solutionreadily accepted by your employees can achieve long-term success. This is whyour system enables you to do everything you want and can be operated easilyand intuitively by your users.

We take the requirements of everyday users of SAP PM very seriously. We listento what you want and work closely with our customers to develop newfunctions. All of our development team has direct contact with the programusers � the only way to truly satisfy the wishes of the end-user. Our developersvisit existing and potential customers, analyze processes on site and listen towhat the users themselves have to say.

Customer Feedback is CrucialThe views of those using our programs are extremely important and wetherefore invite users to test our latest developments before releasing them ontothe market. To offer still better support, we maintain close contact withnumerous organizations and working groups, including the American SAP UserGroup (www.asug.com) and German SAP User Group (www.dsag.de).

We would relish the opportunity of working with you. Why not check out ourhomepage: www.sap.com/pm; and if your company is already an SAP customer,you can access service.sap.com/pm.

Tailored to Your

Working Environment

Our software is tailored directly to the roles of the employees in yourmaintenance organization. Once logged on, the maintenance manager,maintenance engineer, maintenance planner, maintenance supervisor andtechnician will find exactly the functions they require for their daily work. Theworkplace can be customized to suit individual requirements, further enhancingusability.

Our Model Company:

Great Flakes

You will find many references to our employee roles throughout this brochure.To demonstrate the functionality and effectiveness of our asset lifecyclemanagement solution, we will take you through the daily maintenance workperformed at our model company, Great Flakes � a manufacturer of cerealproducts:

■ Peer over maintenance manager Peter Schneider�s shoulder as he controls themaintenance budget or creates cost comparisons for Great Flakes.

■ See how maintenance engineer Harry Meyers draws up blueprints for the newpackaging plant at Great Flakes, then enters and manages the master data.


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■ Sit alongside maintenance planner Petra Schmidt when she sets up orders,before planning resources and dates for the necessary work.

■ Watch with interest how maintenance supervisor Wolfgang Petersen managesthe daily work in his workshop and ensures maintenance tasks are executedcorrectly and on-time.

■ Take a closer look at technician Tanja Schulze executing and confirming herdaily maintenance work � planned and unplanned � on the technical assetsat Great Flakes.

Fig. 1-3: SAP PM - Focusing on the People


1-5

Can be Used in All Industry SectorsSAP PM supports all sectors of industry. Our customers are drawn from thefollowing areas:

■ Automotive industry ■ Paper industry

■ Chemical industry ■ Petrochemicals

■ Commerce / service ■ Pharmaceuticals

■ Electronics ■ Precision engineering

■ Energy suppliers ■ Primary industry

■ Food industry ■ Public utilities

■ Mechanical engineering ■ Publishing

■ Metal-working ■ Software and EDP

■ Mining ■ Transportation

Unbeatable VersatilitySAP PM offers a range of functions that is unsurpassed. They can support youin any situation, whether it be maintenance details within the plant orinternational processes that affect the whole company. No other system is soversatile.

SAP PM is Made-to-MeasureSAP PM is not an off-the-peg product, a one-dimensional solution that requiresyou to start all over again. It can be tailored to suit the individual requirementsof your company. By working closely with us and our partners, you can haveSAP PM made to measure for your company, yet still use a standard system. Thismeans that your version of SAP PM can be upgraded or adapted at any time tosuit different requirements.

Integrating Your

External Systems

SAP PM is an open system. Do you use geographical information systems? Doyour users work with systems for plant data collection? Are you used to enteringmeasurement and counter readings? Then choose SAP PM. It provides moreoptions for integrating external systems than any other system for asset lifecyclemanagement.


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Uniform Asset Lifecycle Management

Across the Company and

Internationally

SAP PM is integrated. As part of mySAP.com, SAP PM guarantees lean, effectivebusiness processes. The latest information from each enterprise area is on-handimmediately, whether it be from human resources, controlling, production orpurchasing. SAP PM connects your asset lifecycle management to the wholecompany, even for multinational groups. Do you want your plants in GreatBritain, France, Germany and Italy to use the same asset lifecycle managementsystem? Choose SAP PM and there is no need to decide on a single languagefor all of these users. We support a number of languages, so every user can workin their own language � a giant step towards system acceptance.

Structuring to Suit Your Needs SAP PM represents your organizational structure individually and flexibly. Youcan use our organizational units to structure your maintenance work accordingto your own criteria. Whether these criteria are locational, functional,responsibility-based or business-driven, our versatility gives you the freedomto realize your very own solution.

Optimizing Your Processes

SAP PM helps you to optimize all of your processes for asset lifecyclemanagement:

Saving Time When Time is Money ■ Breakdown maintenanceTo enter malfunction reports quickly and simply, you require functions thatare easy-to-use. When you need to act immediately, you can enter all theavailable malfunction data on a single screen, add order data and print thenecessary shop papers for your technicians straightaway. This can save youvaluable time.

Specific Planning and

Efficient Controlling

■ Corrective maintenanceWhen work has to be planned comprehensively, SAP PM offers you a wealthof possibilities. Do you want to plan operations, staff, materials and otherresources, and check their availability? Do you need to specify dates, requestpermits, check budgets and track costs? Would you like to use data fromprevious work as a template? Do you want to monitor work progress andconsumption of resources or costs? We supply the functions you need � clear,easy-to-use and at any level of detail.


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Reacting Flexibly to

New Demands

■ Inspection and preventive maintenanceOne of the most important tasks of asset lifecycle management is to preventbreakdowns. Do you want to avoid repair costs and the sizeable costs thatfrequently result from a production shutdown? Does your company have tocomply with ever-stricter health and safety regulations? Have manufacturerguidelines or specifications for quality assurance made you reconsider yourmaintenance strategies? SAP PM provides you with the ideal tool for yourpreventive maintenance. You can use it to safeguard and increase theavailability of your objects and adapt effortlessly to new requirements.

Establishing

Universal Processes

■ Exchange and refurbishment of repairable sparesThis core process in asset lifecycle management requires good communicationwith materials management. Here too you can count on SAP PM, the businessknow-how of SAP AG and our considerable experience. You are using softwarecertified as �ergonomic� by the international norms, ISO 9241 and ISO 12407.This signifies universal, seamlessly integrated processes that track each phaseof the refurbishment cycle � from procurement, warehouse storage, productiveuse and continued refurbishment to scrapping.

Working Together

Successfully

■ External resource managementYour company almost certainly uses external companies, where necessary,for specially qualified personnel, to reduce capacity overloads or for financialreasons. It is therefore imperative that internal and external employees worktogether successfully.

Fig. 1-4: Successful Collaboration with External Companies


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SAP PM is seamlessly integrated with procurement. This means you canrepresent the distribution of tasks at your chosen level of detail:◆ Simple reference to the required material◆ Seamless inclusion of services in the required work◆ User-friendly standard service catalogs available online◆ Flexible processing using outline agreements

Safety � The First Priority ■ Work clearance managementDo you need to implement work safety measures, such as lockout/tagout, fireor radiation protection for maintenance work on technical objects? Workclearance management from SAP PM has already proved its worth in highlysensitive technical systems. It guarantees a safe working environment foryour maintenance staff and enables you to observe environmentalregulations and ensure the reliability of your technical systems.

Planning Complete Projects ■ ProjectsDoes your company regularly make revisions? Does it invest in new technicalsystems and modifications? You can use SAP PM to represent such projectsat conception � in asset lifecycle management. The work can be broken downinto individual project steps that are linked together. Displaying dependenciesis extremely important, and here too SAP PM is a solution you can trust.

Fig. 1-5: Controlling Project Progress Using SAP PM

Investment management is used to monitor accounting, whilst budgetmanagement can also be used for all work.

Identifying Possible Improvements

and Achieving Success

■ AnalysesSAP PM offers versatile analysis and evaluation options to help you assessyour strategies and identify potential for improvement. SAP PM provides youwith key performance indicators, an early warning system and history. Thesedifferentiated analyses make your decisions easier. SAP PM supports you inthe continual improvement of your maintenance processes � the goal ofevery maintenance management team.

Example Assets

2-1

Example Assets

Highlights

The cornerstone of successful asset lifecycle management is clear, open,information-oriented structuring of objects. One system makes it possible torealize Total Productive Maintenance (TPM) � and that system is SAP PM �irrespective of whether you work with fleet objects, power stations, buildings orpower supplies.

You can choose the desired view for your objects: object-based, function-based,structured by type or individual object, single-level or multi-level. SAP PM willfind a particular object for you, whether it is installed, in stock, in the workshopor in transit.

Our unsurpassed range of options enables you to find exactly what you need.Objects are structured ideally to suit the processes in your operational systemand your safety requirements.

Clear Asset Lifecycle ManagementSAP PM can make clear, transparent asset lifecycle management a reality inyour company. Our various structuring options are derived from the differentviews provided for your maintenance objects:

■ For object-based structuring, you sub-divide a technical asset into individualobjects � pieces of equipment. By equipment, we mean every object that youcan manage and maintain as an autonomous unit.

■ For function-based structuring, you sub-divide a technical asset hierarchicallyusing functional locations. Functional locations describe the sites wheremaintenance tasks are executed according to functional, spatial or process-oriented criteria.

Example Assets

2-2

The combination of equipment and functional locations to represent yourobjects creates many new possibilities. By using functional locations to structurethe objects to be maintained, you have already defined the possible installationlocations for objects that you have represented as pieces of equipment. Here isan example:

Fig. 2-1: Structuring of Objects Using SAP PM

Hard Facts Instead

of Guesswork

SAP PM offers you access to a history to evaluate individual objects and thelocations where the objects were installed. This data can prove unequivocallywhat previously you could only suspect (for example, that pumps at aninstallation location with less than 50 kW output have to be replaced far morefrequently than higher performance equipment). SAP PM shows you whichfunctional asset areas are adversely affected by the breakdown of an object andimmediately provides data to help search for suitable replacements.

However, equipment and functional locations are only the tip of the iceberg inensuring that SAP PM satisfies your individual needs.

Over the course of this unit, you will find six practical examples from our modelcompany, Great Flakes, of how to:

■ Represent individual objects: Automobile■ Structure complex technical systems: Power station■ Represent inventory-managed objects: Hardware■ Manage real estate: Building■ Classify objects: Electric pumps■ Integrate external systems: Geographical Information System

Example Assets

2-3

These examples will illustrate the unprecedented range of options available withSAP PM. You can find a complete list of the possible functions in SAP PM atthe end of this brochure under �Range of Functions�.

Example 1: Individual Object (Automobile)

Easy and ClearAt Great Flakes, the maintenance planner Petra Schmidt is responsible formanaging and maintaining automobiles. SAP PM enables her to structure andmanage these individual objects effectively. When automobiles are representedin SAP PM, a large amount of data is recorded that can be used for subsequentevaluations. The following questions are important for the maintenance plannerand can all be easily answered using SAP PM:

Answers to

Everyday Questions

■ Which individual data does an automobile have (for example, model,warranty period, license plate, vehicle and chassis type identification number,height, width or engine performance)?

■ What maintenance work has been performed in the last year (for example,radiator repair or repairs from an accident)? Is a history of this work availablefor each automobile?

■ What were the costs of maintenance work on a particular automobile?■ How high was the average consumption for the individual manufacturer

types?

Fig. 2-2: Individual Object: Automobile

Individual Vehicles or Complete

Fleet Management

In addition to technical management of automobiles, Petra Schmidt uses SAP PMto organize the business processes for the fleet. SAP PM supports her with dailytasks, such as resource planning for automobiles and employees, procurement andrefueling.

Example Assets

2-4

By using SAP PM and its integration with other components, she can representthe infrastructure, and technical or business perspectives of Great Flakes in onesystem. It is irrelevant whether complete fleet object management is required.In each case, SAP PM helps the maintenance planner to optimize her processesand provides cost transparency.

Example 2: Complex Technical System (Power Station)

Complex Technical

System Clearly Displayed

SAP PM has long been successful in structuring large technical systems. Ourcustomers in the chemical and pharmaceutical industries use SAP PM torepresent extremely complex production plants clearly and in a way highlysuited to the special requirements of their industries.

The structuring tools available with SAP PM also achieve extremely impressiveresults for power generation. The following example of a gas power station atGreat Flakes demonstrates just how successfully our standard software can betailored to the requirements of asset lifecycle management for power stations.

Standardized Representation The complete power station has been structured using SAP PM according to theguidelines set out by the general design criteria for power plants. Thisstandardized key contains exact organizational specifications from the topstructure level to the very bottom, providing the platform for unambiguouscommunication.

Fig. 2-3: Standardized Structuring of a Power Station

Structuring to Suit Your Needs As you might expect, SAP PM also allows you to discard the generic keystructure and use individual descriptions � a facility valued by many of ourcustomers. Our company, Great Flakes, has taken the opportunity to incorporatewidely recognized object and structure names into their structuring, so thatusers can still refer to familiar object names.

Example Assets

2-5

Installation Location

and Object with SAP PM

What Harry Meyers, the maintenance engineer at Great Flakes, likes most aboutSAP PM is its flexibility. He can not only refer specifically to certain objects,but target their installation locations as well.

Fig. 2-4: Installation Locations and Objects

SAP PM provides Harry Meyers with a variety of tailor-made evaluations fromwidely different viewpoints, for example:

■ For which product do motors have the lowest breakdown rate at a particularinstallation location?

■ How old are the motors installed at critical positions in the technical system?■ Are enough replacement motors with specific performance features held in

stock, to be exchanged, if necessary, at critical positions in the technicalsystem?

Different Views of

the Same Structure

SAP PM makes multiple labeling of the technical system with different keys verystraightforward for Harry Meyers. The chemical engineers and control engineersat Great Flakes each obtain their own view of the technical system and use theirfamiliar keys for the corresponding objects.

As you can see, our flexible structuring tools can be used to represent yourobjects clearly and specifically to suit your individual requirements. If you area professional supplier, you should find out more about our industry solution,SAP Utilities, which has developed solutions especially for your processes inconjunction with an SAP PM tailored to your needs.

Example Assets

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Example 3: Inventory-Managed Objects (Hardware)

Serialization and

Individual Maintenance

Do you have many similar objects in your company that you want to manageas stock items? Have you already labeled them as individual items with serialnumbers? Would it not be practical if you could manage and maintain all theseindividual objects at the same time?

This is precisely what our customers who manage hardware, such as PCs,monitors and printers want. Likewise our customers who maintain productionresources, such as pumps, motors and valves. They use SAP PM because it worksthe way they do.

Inventory Management and Maintenance Seamlessly IntegratedAutomatic Serialization

Upon Goods Receipt

PCs are also supplied to Great Flakes. When the goods are delivered, the systemgenerates serial numbers, thereby identifying individual technical objects. If, forexample, twelve new PCs of type A have been delivered and three of type B, thenSAP PM now recognizes each PC as an individual object. A considerable amountof important data is recorded automatically, for example, who delivered the PC,where it is located, and the batch to which it belongs.

Individual Management

and Maintenance

Each PC is now managed and maintained in SAP PM as an independent,autonomous unit. The prerequisites are fulfilled immediately by the system sincethe following data is recorded when the goods are delivered:

■ How much did the PC cost?■ When was the PC acquired?■ How much memory space does the computer have?■ How fast is the processor?

Once the PC has been configured and delivered to the user, the following datais added to the master record:

■ Which software has been installed?■ To whom is the PC assigned?■ At whose work station, in which office, in which building is the PC currently

located?

History for Each

Serialized Object

This means that Great Flakes also has the option of creating an individualhistory for each PC, enabling the responsible technician, for example, to answerthe following questions:

■ How often has memory space been installed on the PC? How much memorydoes it now have?

■ Has the graphics card been changed? What resolution does the card nowinstalled have?

Example Assets

2-7

■ Has the PC had a virus? If yes, which areas were affected and had to bereinstalled?

■ How often has the PC been moved between offices? Was it damaged duringa move?

■ When was the PC last repaired and why?

Software Licenses Also

Inventory-Managed

The PC software installed is also managed in the inventory at Great Flakes. Ourmodel company acquires a certain number of licenses for a particular programfrom the software manufacturer. Each installation is posted as a goods issue tothe cost center of the recipient. This enables Great Flakes to control the numberof installations, whilst the responsible technician can monitor which softwareis installed on which PCs.

Take a look at the process for inventory-based management of objects at GreatFlakes:

Fig. 2-5: Example Process for Inventory-Based Management of Objects

Example Assets

2-8

Example 4: Real Estate Management (Building)

Organizing Building

Inspections Effectively

The maintenance planner, Petra Schmidt, must manage numerous buildings at GreatFlakes, for example, office buildings and factory buildings. Many objects in thebuildings must be regularly inspected, such as heaters, fire doors, fire extinguishersor elevators. SAP PM is again ideally suited to meet such requirements. Thefollowing example illustrates its successful implementation and the resultingbenefits in real estate management, focusing on the following questions:

■ How can maintenance costs be reduced through building maintenance?■ How can the value of the building be retained through condition-based

maintenance?■ How can inspections and modernization measures for buildings be planned

and processed effectively?■ What are the estimated costs for projects if, for example, a building must be

completely redeveloped or maintenance work is required on the heatingsystem?

The maintenance planner Petra Schmidt can access the data (for example, datesand costs) at any time for similar projects already completed and incorporate itinto future planning. The numerous evaluation options available with SAP PMhelp her to optimize medium and long-term planning.

Professional Real

Estate Management

Next year, Great Flakes plans to introduce additional, professional real estatemanagement by renting out apartments and new houses. Great Flakes receivessupport through the integration of SAP PM, SAP Real Estate and Controlling.Such integration makes the crossover to management of rented property andits own real estate very straightforward.

Fig. 2-6: Example of a Building Structure

Example Assets

2-9

Structuring

Buildings Clearly

Which solution covers all of these requirements? SAP PM. It ensures that GreatFlakes can structure its buildings, the objects therein and important additionalinformation accordingly.

■ Great Flakes represents its buildings in SAP PM as functional locations. Datadefined here includes descriptions of buildings and responsible cost centers.

■ The objects in the buildings, such as the hydraulic motor for the elevator, firedoors or a high-voltage fuse system, are created as pieces of equipment andthe installation location (functional location) specified.

■ The classification of objects at Great Flakes makes it easier, for example, forthe maintenance planner to find information about particular types of heatersor facades.

Example 5: Classification of Objects (Electric Pumps)

More Than Simple Structuring

of Technical Systems

Do you struggle to describe the objects commonly used in your industry sectorwith all their individual features? Using conventional structuring, SAP PM offersyou the option of entering individual characteristics for your objects with ourclassification system.

Asset-Independent...The advantages of the classification system are exemplified by the case of pumpmanagement at Great Flakes. All of its pumps are created as pieces of equipmentand the master records contain data such as manufacturer, model, acquisitionprice, cost center and installation location.

...and Asset-Specific InformationIn addition, maintenance engineer Harry Meyers has used the classificationsystem to save the technical features of the pumps in the SAP System.

Fig. 2-7: Classification and Representation of Technical Features

Example Assets

2-10

He has recorded the individual characteristics of every pump, information thatis linked directly to the master record.

Fig. 2-8: Individual Attributes of Technical Features

Since SAP PM allows you to describe the objects so accurately, Harry Meyers�colleagues can solve the following problems without delay:

Difficult Questions

Answered Easily with SAP PM

■ Some of the PCs used by Great Flakes are out-of-date. The responsibleemployee must find out which offices in certain buildings contain PCs withless than 100 MHz. These PCs must be replaced.

■ A forklift truck is required to change a motor in the technical system.Maintenance planner Petra Schmidt needs to find a vehicle capable of liftinga motor weighing 3.8 tons onto a seven-meter high ramp.

In the same way, Harry Meyers has described the requirements at possibleinstallation locations of objects:

■ A motor has broken down in a technical system at Great Flakes. PetraSchmidt must find an available replacement motor with an output of at least20 kW.

■ A printer must be replaced in the marketing department at Great Flakes. Thereplacement must be a color laser printer that can print at least six pages perminute.

Example Assets

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Exact and Individual

Evaluations

Very exact evaluations are also possible using the classification system. Hereare some examples from daily life at Great Flakes:

■ How many 21� screens from manufacturer XYZ that are less than two yearsold have been reported as flickering or defective in the last six months byemployees at Great Flakes?

■ How many pumps have broken down in the last three months at a particularinstallation location and what were their characteristics?

■ How many outings has the vintage promotional bus, which Great Flakes usesto drive its special advertising campaigns, made in the last 12 months?

SAP PM can answer all of these questions and many more at the touch of abutton.

Example 6: Integration of External Systems(GIS and Power Supplies)

Peter Schneider and Petra Schmidt, maintenance manager and maintenanceplanner respectively at Great Flakes, visit their colleagues at the energy supplier,Eco-Power, to exchange knowledge and study the use of geographical informationsystems (GIS).

Support for

Energy Suppliers

In the energy supply industry, it is normally power supply systems that arerepresented. The employees need access to geographical information andtechnical data at any time. SAP PM also supports customers, such as Eco-Power,with the typical business processes of an energy supplier.

For example, if a power cable is damaged during construction work at Eco-Power,the hotline creates a malfunction report for the affected object. To do this, thehotline employee must know the street in which the damaged power cable islocated. This and other typical requirements are fulfilled through the integrationof SAP PM with a geographical information system.

Example Assets

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Fast Geographical Information -

Where Did the Malfunction Occur?

Once the two systems are integrated, the GIS accesses technical data directlyfrom SAP PM. If employees from Eco-Power need to find the location of atechnical object, the following data is selected:

■ Geographical positionIs an employee looking for the location of a technical object? He can use theGIS to access geographical information at any time.

■ Technical dataWhich technical data or notifications are already available for the affectedobject? How is it classified? What is its position in the hierarchical structure?The connection to the GIS means employees have access to data for thetechnical object at any time.

If the hotline employee creates the malfunction report �Damage to power cableduring construction work� for a selected object, it is irrelevant in which of thetwo systems he or she is working.

Should changes to master data be required, the employee can likewise enter thechanges in either system. The data is then automatically updated in the othersystem using a special form of data exchange.

In addition to the data for asset lifecycle management described here, employeescan also use the GIS to access other data from other areas, such as materialsmanagement or sales and distribution.

Processes in Asset Lifecycle Management

3-1


Highlights

SAP PM stands for professional processes in asset Lifecycle management. Itoffers you the widest range of options for executing your maintenance tasks. Weare certain that you can represent all of your processes optimally with SAP PM.

Our processing is based on grouping together all the operations required toexecute maintenance work. Maintenance work is executed to determine the actualcondition (inspection), maintain the target condition (preventive maintenance)or return the target condition (repair) of a technical system.

Fig. 3-1: Overview of Asset Lifecycle Management

In this unit, we will illustrate how Great Flakes uses SAP PM in seven exampleprocesses. The processes are distinguished by the following factors:

■ Urgency and scope for planning of execution■ Use of external companies■ Inclusion of other enterprise areas, such as inventory management or

controlling■ Reusability of the objects maintained


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As you would expect, all of our standard processes satisfy internationalrequirements and can be combined, thereby fulfilling all of your maintenanceneeds. But the proof of the pudding � as we shall see at Great Flakes � is in theeating.

Breakdown Maintenance Just how fast can our model company correct malfunctions using SAP PM? Inour example of breakdown maintenance, we demonstrate how to repair objectsquickly and still retain breakdown information for subsequent evaluation.

Corrective Maintenance What package do we offer for corrective maintenance? See our comprehensiveoverview of the diverse functions available with SAP PM � exemplified by seeingcorrective maintenance in action at Great Flakes.

Inspection and

Preventive Maintenance

How does Great Flakes avoid extensive maintenance work right from the start?We reveal all in our section on Inspection and Preventive Maintenance.

Work Clearance Management Do you have critical technical assets that require very tight safety measures formaintenance work? As you will see, work clearance management with SAP PMensures a safe working environment before and during work.

Refurbishment Are you aware of the support we provide for refurbishing your technical objects?Read more about how Great Flakes processes refurbishments.

External Resource Management Do you assign a lot of maintenance work to external companies? Our examplescenario from Great Flakes will highlight that external resource management isone of our leanest processes.

Do you manage your maintenance work regularly in large projects? Then readon to see why Great Flakes opted for SAP PM.


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Breakdown Maintenance

Repair work comprises all the tasks performed in order to return to the targetcondition of your technical assets. Breakdown maintenance means that abreakdown or considerable reduction in performance of one of your systemsnecessitates maintenance work almost immediately. The required tasks willusually have to be executed straightaway.

Critical Factor: SpeedYou therefore need to choose a maintenance process that only contains thosesteps required to request, plan, execute, complete and settle the maintenancetasks.

Fig. 3-2: Breakdown Maintenance

Model Case Scenario:

Great Flakes

The rolled oats packaging machine at Great Flakes has just broken down. Themalfunction must be corrected immediately. Maintenance supervisor WolfgangPetersen describes in a notification how the technical system suddenly stoppedworking. He requests maintenance work, automatically generates a rush orderand prints the shop papers for his employees. All of this is completed quicklyand easily on a single screen. The maintenance supervisor releases the order andensures it is executed. Then Wolfgang Petersen merely has to confirm the actualdata and complete the order. And that is the complete process for breakdownmaintenance, done and dusted.


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Simple Postprocessing

of Notifications

Since time was a critical factor before the tasks were executed, WolfgangPetersen can now add any missing data to aid subsequent evaluations.

Fig. 3-3: Five-Phase Model for Maintenance

Corrective Maintenance

Of course, your employees not only correct malfunctions and repair machinesthat have just broken down. They are also responsible for maintaining all of yourtechnical assets throughout the year. SAP PM supports you with its extremelybroad range of intelligent functions that suit your corrective maintenancerequirements.

Tanja Schulze, the technician at Great Flakes, has noticed a small tear on thefunnel of the rolled oats packaging machine. She also reports occasional noisescoming from the packaging conveyor belt. As the maintenance planner, PetraSchmidt knows it is not necessary to turn the machine off immediately.Nevertheless, it should be checked this week and repaired if necessary.


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NotificationUsing Previous Notifications

as Templates

Petra Schmidt creates a malfunction report, in which she enters the equipmentnumber of the packaging funnel. She is able to use important data for this froma previous notification, so she simply uses the latter as a template for the currentmalfunction report. SAP PM thereby helps her to save a considerable amountof time when entering data.

Automatic

Data Transfer

The maintenance planner also creates another notification containing theassembly number of the conveyor belt. SAP PM automatically copies any otherimportant data for these technical objects from the master records, including theinstallation location, cost center or employees responsible for execution. PetraSchmidt also describes in detail the condition of both technical objects in themalfunction reports.

Fig. 3-4: Notification Structure

The technician had only notified Petra Schmidt of the factory building wherethe machine is located. She therefore enters missing information about thepackaging machine retrospectively.


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Solution Database Since maintenance manager Peter Schneider is not yet certain what caused thereported malfunctions, he consults our Solution Database � an expert SAPsystem � which helps him search for the error and a possible solution to theproblem.

The Solution Database manages symptoms and solutions. Peter Schneider entersa description of the machine error as the symptom. Solutions explain how theproblem can be resolved. When building up the database, any number ofsolutions can be assigned to each symptom, and any number of symptoms canbe assigned to each solution.

Fuzzy or Exact Search Peter Schneider chooses to run a fuzzy search. He merely enters several keywords that the system should search for in the database. If he knew the keys ofthe damage codes used when building up the database, he might prefer to runan exact search. In this case, he would enter the keys and obtain an exact searchresult.

Dates Petra Schmidt enters the basic dates for the order, for example, the time whenthe notification was issued, start of the malfunction, required end date for thework and timing of technical checks.

Damage Catalog System Petra Schmidt does not describe the individual details in a text. Instead she usesthe flexible catalog system that allows her to evaluate data easily. The catalogsystem can manage data, such as damage, causes of damage, affected objectparts and tasks.

PlanningOrders Petra Schmidt uses our order to plan repair work. It is an extremely efficient tool,

providing first-class scheduling options to ensure optimal use of availableresources. Availability checks for material, personnel and production resourcesand tools ensure the process runs smoothly. Permits and integrated workclearance management guarantee that all legal regulations and requirements setout by the manufacturer of a technical asset are observed. Cost overviews makethe processes transparent.


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Petra Schmidt generates one order from the two malfunction reports.

Fig. 3-5: Order Structure

Sub-OrdersIn the meantime, maintenance engineer Harry Meyers has discovered that thenoises from the conveyor belt are being caused by several different factors,whose correction must be organized by other planning departments. Hetherefore creates additional sub-orders in the order so that individual sectionsof the work can be planned proficiently.

Order HierarchyThe resulting order hierarchy has numerous advantages � organizationalstructuring of the orders enables SAP PM, for example, to reconcile all the dateswith one another. The maintenance manager Peter Schneider obtains anexcellent overview of costs for all the orders that he can later settle separately.

WorkflowPeter Schneider uses workflow to inform the production manager that amalfunction has occurred.

Individual StepsFor each order or sub-order, Petra Schmidt also plans in detail the individualsteps to be executed later. She describes the step, then specifies the workshopinvolved and estimated work required.

Task ListThe maintenance planner had already created a task list for correcting this typeof damage to the packaging conveyor belt because it always requires the samefixed sequence of steps. Now she can choose the necessary steps from this tasklist and incorporate them into the order.


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Maintenance Group

Executing Work

Petra Schmidt also specifies which maintenance group should execute the workand which maintenance group is in charge. The maintenance manager PeterSchneider has structured all of the maintenance groups hierarchically in SAP PMand maintained the following data:

■ Operating times of maintenance group■ Resources of maintenance group, for example, individual people, groups of

people or machines■ Labor costs■ Employee qualifications■ Shift schedule and calendar, since work also continues at Great Flakes outside

of regular working times.

Available Capacity SAP PM uses this data to determine the capacity available for each maintenancegroup.

Capacity Requirements Petra Schmidt specifies how long the planned tasks should take. SAP PM usesthis information to schedule work steps as ideally as possible and optimize theuse of free capacity.

Scheduling The maintenance planner knows that the work can only be started next Mondayat the earliest, as another production order is currently in process on thetechnical asset. This is not a problem for SAP PM. You enter this date and allowthe system to schedule all the other operations as effectively as possible. Inaddition to scheduling forwards, the planner could also schedule backwards tohave the work executed on the same day.

Material Availability Check Petra Schmidt knows that a new outer cover is required to repair the funnel. Thismaterial �outer funnel cover� is kept in stock in the warehouse at Great Flakesand has been represented using SAP PM as part of the funnel bill of material.Petra Schmidt uses the material availability check to determine that the requiredouter cover is currently available. As soon as the maintenance planner hasentered the cover in the order, SAP PM reserves the cover automatically.


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Fig. 3-6: Availability Check

External MaterialHowever, to repair the conveyor belt, a new motor is needed that is not kept instock, since this type of motor is rarely used at Great Flakes. The technicaldescription given by Petra Schmidt is automatically forwarded to the purchasingdepartment.

Material from

Internet Catalogs

Petra Schmidt often selects external material for an order from catalogs that shecan access from the Internet or Intranet using an interface to SAP EnterpriseBuyer Professional Edition. This option means she always has currentmanufacturer data available. She also frequently browses through catalogssaved as CDs on fixed data media for external material and then requests it.

Estimated Costs

and Order Budget

Naturally, the maintenance manager Peter Schneider is trying to keep costs aslow as possible for this repair order, and SAP PM makes this straightforward.He enters his cost estimate in the order itself and assigns his budget to the order.

PermitsVarious rules and regulations must be observed when the rolled oats packagingmachine is repaired. These include a directive from the health authority that allemployees involved with the repair must wear gloves. Once the maintenanceengineer has checked this, he grants the relevant approval. Now the repair workcan begin.


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SchedulingShop Papers Petra Schmidt releases the work order for execution and prints the shop papers

for the maintenance group that will execute the work. The technician TanjaSchulze now withdraws the outer funnel cover from the warehouse, collects themotor that has been purchased and then starts to repair the rolled oatspackaging machine.

Material Withdrawal Tanja Schulze also withdraws other materials from the warehouse, where thesenior stores technician records the withdrawal.

ExecutionActual Costs SAP PM automatically determines the current actual costs. These costs arise

once the technician has withdrawn the required material from the warehouse,the invoice for the material purchased externally has been entered, or actualtimes have been confirmed.

Costs Overview SAP PM displays all the estimated, planned and actual costs, clearly sorted bycost element, in an overview so that the maintenance manager can easilymonitor the costs for an order.

Order CompletionTime Confirmation Tanja Schulze uses a central confirmation function to confirm actual time data

on a single screen. For each completed step, she specifies her name or that ofthe workshop executing the work. To record her work progress, Tanja enters apartial confirmation. Once the entire order has been executed fully, she enters afinal confirmation.

Technical Confirmation The technical confirmation, for example, provides maintenance manager PeterSchneider with a database for evaluations, such as Mean Time To Repair (MTTR),Mean Time Between Repairs (MTBR) and Mean Time Between Failures (MTBF).The technician Tanja Schulze therefore confirms the cause of damage, durationof machine breakdown and other system availability data.


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Fig. 3-7: Completion Confirmation

Technical CompletionMaintenance planner Petra Schmidt then closes the malfunction reports andtechnically completes the order with its sub-orders, whereupon the data can nolonger be changed. Remaining reservations and outstanding, unplannedcapacities are cancelled. However, the order and its sub-orders can still receivecosts, for example, through the receipt of invoices for materials delivered.

Business CompletionSince Petra Schmidt no longer expects costs to be posted, she also performs abusiness completion for the order. SAP PM nevertheless enables both thetechnical and business completions to be reset if other changes are required.

The maintenance planner finds it helpful that order data is still available afterthe business completion because it can be used to plan future work even moreexactly.


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Inspection and Preventive Maintenance

Increasing

System Availability

One of the most important tasks of asset Lifecycle management is to ensure thelong-term availability of technical objects. In addition to maintenance costs, thebreakdown of technical systems or other objects often results in much highersubsequent costs owing to production breakdown.

SAP PM is the ideal instrument to help you avoid these costs. It supports youduring the planning and execution of efficient inspections and preventivemaintenance of your objects.

The maintenance engineer Harry Meyers and maintenance planner PetraSchmidt work closely together to ensure that the inspections and preventivemaintenance tasks performed at Great Flakes are correctly represented in SAP PM.Our SAP PM solution helps you in your everyday work to:

Working More

Effectively

■ Comply with rules and regulations (for example, adherence to industrialhealth and safety standards)

■ Follow manufacturer recommendations and observe environmentalrequirements

■ Guarantee quality assurance (for example, customer inquiries)■ Reduce the frequency of object malfunctions and lengthen the object lifecycle■ Improve your planning and distribution of capacity

Fig. 3-8: Types of Preventive Maintenance

Identifying and Planning Maintenance Work

The following business processes should be represented at Great Flakes:

Single Cycle Plans for Simple

Maintenance Cycles

Example 1: Routine maintenance work must be executed regularly at sometechnical objects. For example, an annual safety check should be performed onforklift trucks or a visual check made of the packaging conveyor belt every 500operating hours.


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The maintenance planner Petra Schmidt creates a maintenance plan for thesemaintenance tasks and defines one time-based or counter-based maintenancecycle.

Task Lists for

Standardized Procedures

She uses SAP PM to define work that consists of a series of standardized steps(for example, switching off, safety check, electrical separation of objects andswitching on) in a task list and then includes these in the maintenance planswhenever required. This reduces the time required to enter data. Petra Schmidtalso defines the time and resources, such as work groups, utilities or materials,required to execute the work in the task lists.

Fig. 3-9: Task List

Strategy Plans for

Sophisticated Maintenance Cycles

Example 2: The technician at Great Flakes must inspect certain parts of thetechnical objects at different intervals. For example, an external visual checkof the water pumps is required each month to look for rust or leakage. Theabrasion of the gearwheel in the pump gear, however, is only checked annually.

Time-Based MaintenanceThe maintenance planner uses the different maintenance cycles (in this case,monthly and yearly) to set up a time-based maintenance strategy in SAP PM,with which to plan and execute efficient preventive maintenance.

Performance-Based

Maintenance

Example 3: Various maintenance tasks should be executed on the pumpsdepending on throughput. For example, Petra Schmidt must ensure that a safetycheck of the operational system is made after 50,000 liters throughput and thatall the seals are changed after 100,000 liters.


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This type of preventive maintenance can be planned and executed easily usinga performance-based maintenance strategy with regularly updated counterreadings. When new counter readings are available, SAP PM automaticallyadjusts the calculated maintenance dates.

Fig. 3-10: Representation of Maintenance Plan Types in SAP PM

Condition-Based

Maintenance

Example 4: The temperature in the drying ovens at Great Flakes must bemonitored. If the temperature in one of the ovens reaches a critical level, amalfunction code is sent automatically to SAP PM using a radio signal and anotification generated. The technician Tanja Schulze is immediately notified ofthe malfunction and can examine the damage. The malfunction is transmittedusing a SCADA (Supervisory Control And Data Acquisition) interface.

Multiple Counter Plans Example 5: The oil in the hydraulics must be changed for the fork-lift trucks atGreat Flakes either after one year, 1,200 operating hours or 5,000 miles. GreatFlakes uses SAP PM to control whether the date should be due when the firstevent occurs (one year) or only once all three events (one year, 1,2000 operatinghours and 5,000 miles) have occurred. Petra Schmidt creates multiple counterplans in SAP PM to plan and execute this task.

Calibration of

Test Equipment

Example 6: Harry Meyers is responsible for quality planning at Great Flakes andconsequently the inspection of test equipment. He must organize regularmonitoring of the depth gauge and would like to check the measurementreadings for the characteristics �Grinding length� and �Measuring pin diameter�.If the measurement readings taken during an inspection lie outside of thetolerances allowed, then the gauges must be adjusted.

Inspection by

External Companies

Example 7: The elevators at Great Flakes should be maintained every 12 monthsby the external company, Kwik Fix.


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Executing and Monitoring Preventive Maintenance Work

Once you have identified and represented the maintenance work in yourcompany, SAP PM supports you in your everyday work and the execution ofthe preventive maintenance itself.

Do you want your maintenance work determined automatically? Then use SAP PM.By scheduling maintenance plans, SAP PM automatically generates orders andnotifications for the work due. When you confirm the completed work, SAP PMagain automatically adjusts the future dates.

Setting Scheduling

Parameters Flexibly

Do you want to adapt scheduling completely to your requirements and reactflexibly to new situations? This was the goal at Great Flakes. The maintenancemanager Peter Schneider therefore asked a considerable number of questionswhen Great Flakes implemented SAP PM. We answered his questions as follows:

■ Are subsequent dates moved automatically if work is executed too early or toolate?This can be tailored to your individual needs. You can define whether, andto what extent, differences should affect further scheduling, and whatdifferences should be tolerated.

■ Are due orders and notifications available for processing before the due date?Yes. You can define how far in advance of the actual execution date the orderor notification should be available in SAP PM.

■ Can we change maintenance cycles defined in the maintenance plan?Yes. You can shorten or lengthen cycles individually in the maintenance plan.

■ Which scheduling types are available?Time-based and key date-based scheduling, scheduling by factory calendarand performance-based scheduling. This allows tremendous flexibility,whereby you can even incorporate public holidays or works holidays intoyour planning.

■ Is a new order always generated � even if the work has not yet beencompleted?This is entirely up to you. You can define that confirmation is obligatory, toensure, for example, that the next due order is only generated once theprevious order has been confirmed.

■ Can we display dependencies between cycles?Yes. You can define relationships between maintenance cycles for multiplecounter plans. You can define when maintenance work is due � as soon as oneof the two conditions has been satisfied or only when both have been met.


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■ What happens if maintenance cycles involving similar work are due on thesame day?If, for example, comprehensive and minor inspections are due on the sameday, you can decide which cycle should actually be executed. In this case,only the comprehensive inspection, since it will encompass the minorinspection.

■ Does SAP PM provide an overview of upcoming maintenance work?Yes. SAP PM provides you with an overview of all upcoming maintenancework and the objects at which work should be executed. This overview isavailable as a list or graphic.

■ Is it possible to simulate dates and planned changes?Yes. You can use the scheduling simulation to simulate changes and displaythem graphically. You can also simulate date shifts to establish the best datefor optimum capacity load utilization.

Fig. 3-11: Graphical Scheduling Overview


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Cost Analyses for Task Lists and Maintenance PlansChecking the FiguresWith SAP PM, we have also focused on the central role of cost analysis. You

can use the cost analysis function in SAP PM to determine the costs for completetask lists or individual operations (for example, all operations processed usingexternal resources).

Fig. 3-12: Cost Analysis of Task List

What Does the Future Hold?We have also considered the importance of the cost analysis for maintenanceplans. You can use the cost analysis to determine the costs expected for one ormore maintenance plans in a specific analysis period.

For example, the result above shows the sum total of all internal activities,external activities, materials required or costs for one or more maintenanceplans.

You can perform a similar cost estimate in a maintenance plan to determine thecosts incurred by this maintenance plan for a particular period.

As you can see, SAP PM provides professional support with your everyday workin all the key aspects of asset lifecycle management.


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Work Clearance Management

Safety in the Workplace for Asset

Lifecycle Management

Do you have to observe strict health and safety regulations in your company?Is legislation regarding health and safety in the workplace in force or dodirectives exist for using hazardous substances? Then you should utilize theservices provided by work clearance management with SAP PM. It offers youeverything you need for thorough, exact planning and organization ofmaintenance work at technical objects � where consideration of these safetyregulations is imperative.

If extensive safety measures must be enforced before inspections, repairs orpreventive maintenance work are performed and then observed throughout thework, your needs will be ideally served by work clearance management.

Safer Working Conditions Industrial health and safety measures can include fire protection, radiationprotection, directives for using hazardous substances or lockout/tagout. In thecase of lockout/tagout, technical objects are isolated electrically or separatedmechanically from other parts of the technical system whilst work or specialtests are performed.

Many companies that require work clearance management operate in the energysupply, chemical, or oil and gas industries.

Read more about the maintenance regulations at our model energy supplier,Eco-Power, that led them to choose work clearance management with SAP PM.

Protecting the Welfare of Employees ■ The employees in asset lifecycle management at Eco-Power work in a criticalenvironment, where they are exposed to high levels of danger, notably highvoltage, radioactivity and gases.

■ The occurrence of typical work-related illnesses necessitates special measuresto protect the welfare of the employees and prevent such illnesses.

Avoiding a System Shutdown ■ Maintenance work at Eco-Power must also be performed whilst theproduction systems are still operational.

■ The functionality of other parts of the technical system should not be affectedunder any circumstances.

The following example clearly illustrates how work clearance management withSAP PM can be incorporated into the maintenance process, enabling you toimplement work safety measures successfully:

Technicians at Eco-Power have established that a pump in the feed-water systemof the power station is leaking and they therefore create a malfunction report.

Creating a Malfunction

Report and Order

The maintenance planner at Eco-Power creates an order for the malfunctionreport. The system recognizes that a lockout/tagout is required to repair thepump. The maintenance planner cannot release the order for execution, sincethe necessary work clearance management objects must first be created andassigned.


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Creating Work Clearance

Management Objects

Work clearance management objects are used to control work safety measures,such as lockout/tagout. For the lockout/tagout of the pump in the feed-watersystem at Eco-Power, a work clearance application and operational workclearance documents are required.

Depending on the required lockout/tagout, the work clearance requester createsthe appropriate work clearance application and assigns it to the order.

The work clearance planner at Eco-Power assigns the relevant operational workclearance documents to the work clearance application after consulting theirlibrary of work clearance documents. The individual items in these lists containthe technical objects in a technical system to be tagged/untagged or monitoredduring lockout/tagout. The work clearance planner then grants the necessaryapprovals.

Executing Lockout/TagoutThe safety engineer can now initiate the lockout/tagout for the assignedoperational work clearance documents. The technical objects (for example, theleaking pump, replacement pump or butterfly valves in the water circulation)listed in the operational work clearance documents are in turn switched on oroff, separated or connected, mechanically locked if necessary, and identifiedwith operational tags.

Fig. 3-13: Lockout/Tagout of a Technical Object

Following the lockout/tagout on site, the safety engineer confirms the executionin the system.


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Once tagging has been performed for all the operational work clearancedocuments, the work clearance planner confirms their execution in the systemand grants any additional approvals required.

Executing Maintenance Work Only then can the maintenance planner at Eco-Power release the order forexecution. The technicians can now repair the pump in a safe workingenvironment.

After the technicians have completed and confirmed the repair, the maintenanceplanner confirms execution of the work in the order. The requested lockout/tagout is therefore no longer necessary and now untagging � returning thesystem to productive operation � is required.

Untagging The work clearance planner recognizes that lockout/tagout is no longer requiredand closes the work clearance application. This completion enables the safetyengineer to start the untagging for the operational work clearance documents.Once the untagging is completed on site, the safety engineer confirms this inthe system and closes the operational work clearance documents.

Completing an Order The maintenance planner completes the order technically, after which thebusiness completion is performed and the order settled. The order is thentransferred to the order history, where it can be evaluated in the SAP componentPlant Maintenance Information System (PM-IS).

Fig. 3-14: Order Processing with Work Clearance Management


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Exchanging and Refurbishing Repairable Spares

Critical Success FactorIn many companies, the refurbishing of defective repairable spares is critical forsystem availability. This business process requires a high level of integrationbetween the maintenance, materials management and accounting departments.We support you in this core maintenance process with one complete scenariofrom start to finish.

Core Process in Asset Lifecycle

Management

You can fully represent the lifecycle of your repairable spares � from theirprocurement, productive use and repeated refurbishment to scrapping � with anindividual object history if required. You can assign values to the repairablespares depending on their condition. These conditions can be described evenmore exactly using valuation types that can be freely defined.

Refurbishment CycleAs you can see, nobody knows more about integration than SAP. SAP PM makesthe complete lifecycle of your repairable spares transparent and the flexiblerefurbishment cycle can be adapted easily to the individual requirements of yourcompany:

Fig. 3-15: Usage, Storage and Refurbishment of Repairable Spares

A Transparent Process �

Through and Through

Functions in purchase order monitoring provide the responsible employees atGreat Flakes with current information about procurement and repairable sparesso that the location of individual parts can be pinpointed at any time.

If a part in one of the technical systems is defective, for example, it is replacedby maintenance technician Tanja Schulze with an intact repairable spare fromthe warehouse. She also returns the defective part to the warehouse. If the partwas previously labeled �functional� with a particular value, it is now deemed�defect�. The revaluation of such a part is the result of its assignment to a newvaluation type.


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The responsible employee uses the relevant serial numbers to register importantrepairable spares that are managed as individual items of material at GreatFlakes when they are entered and removed from the warehouse.

Installing and

Dismantling with Ease

Maintenance planner Petra Schmidt plans the installation and dismantling ofrepairable spares using the planning and processing functions in the order. Thismakes the exchange of repairable spares transparent and Petra Schmidt cancheck the situation in the history at any time.

Orders Tailored to

Your Requirements

You use the refurbishment order developed especially for refurbishment planning.Here you specify:

■ How many repairable spares of a certain material should be refurbished■ From which storage location and batch the repairable spares should be

withdrawn and to where the refurbished parts should be returned■ Over what period the repairable spares should be refurbished■ Which job steps, materials and other resources are required for refurbishment

Keeping Ahead:

Integrated Order Processing

The integrated functions from materials management support you whenwithdrawing repairable spares and materials required for the refurbishment, andwhen returning refurbished repairable spares to the warehouse.

As in the maintenance order, you can use completion confirmations to checkhow work is progressing.

Once the materials have been refurbished, you complete the order. The datacollected is transferred to the history, where it is available to help evaluateprevious refurbishments and plan future ones.


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Managing External Resources

In addition to your own staff, you almost certainly also use employees fromexternal companies. Since our customers often use very different procedures,we provide a wide range of options to help represent the most diverse types ofexternal resource management. As an example, here are the three ways ofmanaging external resources used at Great Flakes:

Fig. 3-16: Why Use External Resources?

External Resource Management with Individual Purchase OrderOrder-Based

Service Request

Materials and services are purchased individually at Great Flakes. SAP PMgenerates purchase requisitions automatically for the required services.Depending on which is more cost-effective, the settlement is either performedon a resource-related basis or a flat rate is charged for the whole service.

External Resource Management with Service SpecificationsUsing Service SpecificationsSince Great Flakes has long-term business relationships with certain vendors,

the maintenance manager Peter Schneider drafts outline agreements with thevendor that contain service specifications. These agreements cover the validityperiod, purchase quantity, purchase value and conditions for performingservices.


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Once the external employees have executed the work, they enter their activitieson service entry sheets, which are checked by the maintenance supervisor,Wolfgang Petersen. However, he can also record the activities of these employeeshimself.

Fig. 3-17: External Resource Management with Service Specifications

Simplified Form of External Resource ManagementExternal Company On Site For this type of external resource management, Great Flakes has defined the

external company as a group of maintenance workers. The assembly firm, KwikFix, has a small building on site at the Great Flakes plant. The maintenancemanager Peter Schneider creates a time-based outline agreement for thisexternal company, in which he defines the purchasing conditions.

Settling Services Collectively Instead of sending a number of individual invoices, Kwik Fix issues onecollective receipt covering all the work orders executed in a given period,making life much easier for Great Flakes.


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Projects

Planning Large Projects SimplyDo you perform complex tasks that often necessitate shutting down yourtechnical systems for a certain period? For example, are comprehensive safetychecks, modifications, modernization measures or new development projectsconstantly under review? Do you want to ensure that costs do not exceed theplanned budget and that planning of dates and resources is optimized?

We provide you with efficient tools for project management. Take a closer lookat the functions available with SAP PM for processing revisions, complexprojects and investment measures.

Revisions

Revisions generally result in high costs because they require a considerablequantity of resources and need to be completed as quickly as possible to keepproduction shutdowns to a minimum.

Revisions occur once every six months at Great Flakes and usually last threedays. However, the exact date is generally only fixed shortly beforehand, sincethe maintenance work must be coordinated with production.

Grouping Tasks TogetherOver the intervening six months, employees create orders for all the work thatshould be done during the revision, and assign them the same revision number.This enables the maintenance manager Peter Schneider to keep a check on thescope of the planned revision. Once a suitable date has been set, the employeesexecute the tasks as simultaneously as possible within the time planned for therevision.

Project System

Large-scale projects in asset lifecycle management necessitate detailed planning.Most individual tasks in a project are one-off requirements and highly complex.They must be completed in a limited period of time and are both expensive andcapacity intensive. Specific objectives with high quality requirements aregenerally agreed between the sold-to-party and contractor. For this reason, weprovide SAP PM.

General OverhaulThe entire rolled oats packaging machine at Great Flakes requires a generaloverhaul. Regular production should be interrupted for the shortest timepossible. This project is processed in exactly the same way as for breakdownmaintenance with internal and external resources, namely, using notificationsand orders.


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Costs and Budget The maintenance planner Petra Schmidt plans the costs of the general overhaulfor all the orders to be executed when the motor is overhauled. After she hasreleased the order, SAP PM checks regularly whether the planned costs lie withinthe project budget.

Progress Analyses The data confirmed by the technician is automatically entered in the projectdata. A Project Information System supplies current data regarding budget,costs/revenues, dates and resources to the maintenance manager Peter Schneiderat various levels of detail and summarization. Progress analyses keep him rightup-to-date.

Once the project at Great Flakes has been completed, the services providedduring the general overhaul and costs collected for this project are settled to theproduction department that requested the services.

Modifications and New DevelopmentsModernization of

Technical Systems

Owing to increasing technical demands, an ever-greater need for environmentalprotection and the high operative level of industrial systems, technical systemsmust repeatedly be modified or modernized to increase their value. Scrappingold technical systems and replacing them with new up-to-date productionsystems is the job of asset lifecycle management. SAP PM supports you here inconjunction with investment management.

Owing to increased sales and demand, Great Flakes requires a new packagingconveyor belt. The production manager asks the maintenance manager PeterSchneider to install a new packaging conveyor belt. The maintenance plannerPetra Schmidt therefore creates an order. It has already been agreed with assetaccounting that this automatically generates an asset under construction, towhich all costs incurred are settled. Now Peter Schneider can identify in thebalance sheet which items are investments and which are costs, even though theinstallation continues into the next period.

Analyses for Asset Lifecycle Management

4-1


Highlights

Identify your cost factors. Provide verification documents. Demonstrateimprovements in efficiency. Analyze the breakdown record and frequency ofdamage of your objects.

How? � With SAP PM.

We provide the tools you need, tailored exactly to the different requirements ofyour system users. We help you to accelerate and optimize your processes inasset lifecycle management at every level.

Information at Every Level of Detail

Highlighting the Strengths

of Your Asset Lifecycle Management

Fast access to important data is essential for continual improvement of work inasset lifecycle management. You can use SAP PM to highlight how effective yourstrategies are and identify where there is potential for improvement. SAP PM canbe used to access current information from all levels at any time.

Comprehensive Reporting and Detailed HistoryAnswering All Your

Questions Easily

Our reports provide detailed information about maintenance events accordingto freely definable criteria. Here are some examples of questions that can beanswered easily using our reporting functions:

■ Which malfunction reports were recorded for cost center 4711 in a particularperiod?

■ Which maintenance orders have been executed for technical asset 0815 andwhat costs were incurred?

■ What were the last mileage readings measured for the cars in your car pool?■ Which pieces of equipment were installed on a particular day at pumping

station 05P1234?■ Which measurement readings were entered in January for measuring point

1552 (container temperature in operative system)?■ Which serial numbers have been assigned for material HX32?■ Which work centers in plant 1000 are not assigned to cost center 4711?■ Which maintenance dates are scheduled next month for pieces of equipment

and functional locations in plant 0002?■ In which task lists and bills of material is material HX32 used?


4-2

Your Personal View

of Selected Data

All the results are displayed in lists. SAP PM enables each of your users to definetheir own views for selected data. Each result can be displayed immediately inthe preferred view. The user can process this list further, for example, by showingadditional fields, changing the order of columns, sorting or using searchfunctions. He or she can also generate graphics from the list data, send these bye-mail or download them onto a PC.

Calling Up the Data

That You Need

The history created using SAP PM provides detailed analysis options, right downto the level of individual documents. Our experienced development team hasensured that all the data you need can be called up quickly and easily.

An Information System that Makes Decisions EasierAccessing Data

That Helps You

We provide the following flexible tools to help you collect and summarize datafrom asset lifecycle management:

■ Relevant key figures■ Standard analyses whose data is drawn directly from operational use■ Flexible analyses that enable you to collect important data separately and

evaluate data structures

Fig. 4-1: Standard Analyses � Here in the SAP �Internet Demonstration andEvaluation System� (IDES)

Identifying Your Potential We help you to identify problem areas and analyze their origin. You can monitorwhether target criteria are being met successfully and react early to setbacks.


4-3

Asset Lifecycle Management in

a Company-Wide Context

The inclusion of the PMIS in the Logistics Information System (LIS) means youcan view your data for asset lifecycle management relative to the company asa whole. The Logistics data warehouse is also available with the LIS. The datafor asset lifecycle management is transferred to the Executive InformationSystem (EIS). Managers and project leaders can use this data warehouse at anytime to obtain an overview of the critical success factors in the company. Detaildata can also be accessed here, if required.

The Information Center of the Future: SAP Business InformationWarehouse (SAP BW)

Seamless Integration

with Existing Systems

The SAP Business Information Warehouse (SAP BW) represents the highlyefficient, highly competitive future of data warehousing � a complete solutionthat provides you with the latest facts and figures to help answer any numberof questions. The SAP BW infrastructure can be used immediately and integratedseamlessly into your existing system environment.

SAP BW supplies �business content� � preconfigured report and analysistemplates, and contains the technical basis, data extraction and provision,metadata and information models. Master data (for example, functionallocations, equipment or catalogs) and movement data (such as notifications,orders or notification items) is extracted from SAP BW.

Fig. 4-2: Example Evaluation in the Business Information Warehouse (BW)


4-4

Ideal for Your User Roles The personalized nature of the pre-defined business content in SAP BW is ideallysuited for the individual user roles supported by SAP.

Historical Information � Even Without Prior Use of SAP PMTransferring Your Existing

Data to SAP PM

Have you been using a different system for asset lifecycle management, butwould like previously collected data to be available in SAP PM? Our tools enableyou to copy historical data from your legacy system into SAP PM, where it isavailable as if created there directly. There is nothing to lose and much to gainby implementing SAP PM. Read on to find out how we support your employeesindividually.

The Right Tool for Each Employee

SAP PM supports employees in all areas of their work in asset lifecyclemanagement with helpful evaluations. Our role-based application specificallytargets the requirements of the individual employee groups. Here are someexamples of just how flexible our evaluations are:

The Big Picture: Analyses for the Maintenance Manager

Peter Schneider, the maintenance manager at Great Flakes, is directlyresponsible for asset lifecycle management, its budget and the current costs. Hemonitors the overall asset lifecycle management of the operative system. He isalso responsible for staff in the asset lifecycle management department, andmakes decisions about hiring employees and assigning work to service providersand suppliers.

Important Data for the

Maintenance Manager

He requires analyses, for example, that help answer the following questions:

■ What were the maintenance costs in the second quarter of this year?■ What is the relationship between the maintenance costs incurred this year

and the planned costs?■ To what extent has the budget for this year already been exhausted?■ How many employees work in maintenance plant 001 and what are the

personnel costs?■ What is the percentage distribution of damage codes?


4-5

Fig. 4-3: Analyses for the Maintenance Manager

Object Overview: Evaluations for the Maintenance Engineer

Harry Meyers, the maintenance engineer at Great Flakes, draws up engineeringand design plans for technical assets and monitors their construction, soundworking order and maintenance. His area of responsibility also includes enteringand managing master data, bills of material and maintenance plans for thesetechnical assets. He is involved in deciding what maintenance work is executedand supports the maintenance planner with these tasks.

Efficient Analyses for the

Maintenance Engineer

Harry Meyers requires evaluations that support him effectively in his work, suchas the following:

■ Which malfunctions have been reported for the packaging plant in the firstquarter of the year?

■ How is work progressing with the construction of the new oven in hall 2?Can the planned finish date be met?

■ For which technical objects does the warranty expire in the next month?


4-6

Fig. 4-4: Analyses for the Maintenance Engineer

■ Which maintenance plans and bills of material belong to conveyor 002, inwhich several new parts have just been installed? Do they need to be modifiedfor the new technical conditions?

■ How long is the Mean Time To Repair (MTTR) for the maintenance objects inthe North plant in comparison to the South plant?

■ How long is the Mean Time Between Failures (MTBF) for the maintenanceobjects in the North plant in comparison to the South plant?

■ Where are the main focus areas for maintenance in similarly constructedtechnical assets?

■ How many new pump motors have been delivered in the last month andprovided automatically with equipment master records? Has all the detaildata already been entered?

■ Which pieces of equipment head the top 10 list of pumps with the highestmaintenance costs?


4-7

Time-Based Planning: Evaluations for the Maintenance Planner

As the maintenance planner at Great Flakes, Petra Schmidt is responsible forplanning maintenance work based on malfunction reports. She sets up ordersand plans the type and scope of necessary work, the resources and dates, in viewof the operational conditions.

Planning Guide for the

Maintenance Planner

For judicious planning, Petra Schmidt needs evaluations that offer an overviewand consider the current situation of the operative system. Evaluations in SAP PM,for example, can answer the following questions quickly and easily:

■ How many notifications have been entered today, for which no order has yetbeen generated?

■ How many orders have a planned start date next week and are planned forthe mechanical workshop?

Fig. 4-5: Analyses for the Maintenance Planner

■ Which orders have exceeded the time allocated?■ How quickly has the maintenance team reacted to malfunctions (average time

between notification, order generation and completion confirmation)?■ How many actual hours does the mechanics workshop confirm on average

per month?


4-8

Workshop Efficiency: Evaluations for the Maintenance Supervisor

As the maintenance supervisor, Wolfgang Petersen is responsible for the expert,on-time execution of maintenance work at Great Flakes. He is the direct contactperson for technicians, external companies and maintenance planners, andmanages the daily work in the workshop. He also monitors adherence to budgetguidelines for orders and operational rules for processing.

Practical Data for the

Maintenance Supervisor

Wolfgang Petersen requires quick, practical evaluations to provide him withimportant information for his work. Here are some of the questions that SAP PMcan answer straightaway:

■ Which orders must definitely be completed today?■ Which external companies are working on orders this week that have been

assigned to my workshops?■ Which orders processed this month by my workshop have exceeded the

planned budget?

Fig. 4-6: Analyses for the Maintenance Supervisor


4-9

■ Which orders have been processed in the last two weeks by the mechanicaland electrical workshops?

■ What percentage of assigned orders does my team complete within theplanned time?

■ What is the relationship between the attendance hours of my technicians andthe times confirmed by them?

■ Are all my workshops being used equally to their full capacity or are certainworkshops repeatedly overloaded?

Personalized Information: Evaluations for the Technician

Tanja Schulze works as a technician at Great Flakes. She works for WolfgangPetersen�s team and executes the daily work required.

Individual Analyses

for the Technician

Tanja Schulze wants to see the data that directly affects her. Our reports provideher with an overview that answers questions such as:

■ For which orders have I already been scheduled this week?■ For which orders have I confirmed times in the last month?■ How many hours have I confirmed in the last week?

Fig. 4-7: Analyses for the Technician

Integration and Interfaces

5-1


Highlights

SAP PM is a software solution that covers all of your requirements for assetlifecycle management. The uniform graphical user interface is especially user-friendly and the personalization options ensure it is readily accepted. All the dataand functions for your business processes in asset lifecycle management arelinked together without the need for interfaces. The openness of the SAP Systemallows you to integrate many external systems with SAP PM, for example,Geographical Information Systems (GIS), CAD (Computer Aided Design) systemsor Supervisory Control and Data Acquisition (SCADA) systems.

Optimizing Business ProcessesSAP PM is a component of mySAP.com that is integrated with the functions inSAP Logistics, SAP Accounting and SAP Human Resources. The continualexchange of data with other areas of mySAP.com guarantees up-to-dateinformation and the integrated functionality helps to optimize businessprocesses.

We are in constant contact with users from different industry sectors, therebyensuring that experience and knowledge is continually shared.

International and OpenSAP PM is an open system that can be used internationally:

■ We guarantee integration with other application components of mySAP.com.■ We offer flexible interfaces to external systems.

Integration in mySAP.com

SAP PM is integrated with many other components of mySAP.com. Some of thefunctions available are outlined below:

Logistics■ Materials ManagementYou can use Materials Management to represent the processes required tomanage parts or materials. These include the external procurement ofmaterials, services and inventory management functions. Repairable sparesto be refurbished are also managed using Materials Management.

■ Project SystemYou can use Project System within Asset Lifecycle Management to representcomplex tasks that span several orders and for which certain dependenciesexist between the orders.

■ Quality ManagementIntegration with Quality Management makes detailed results available forinspections, thereby enabling a subsequent usage decision. You can use SAP PMto manage the test equipment used in Quality Management.


5-2

Financial Accounting and Controlling ■ Financial AccountingThe integrated use of functions from Financial Accounting enables you tomanage customer and vendor data, as well as create and review invoices.

■ Asset AccountingIntegration with Asset Accounting enables you to settle activities that mustbe capitalized directly to the relevant asset and also create new assets underconstruction. You can display a link between the financial and maintenance-specific views of your assets. You can create asset master recordsautomatically when creating equipment master records and changes arereconciled immediately by the system.

■ Cost AccountingYou can use the functions in Cost Accounting to monitor, allocate andevaluate internal costs incurred by maintenance activities.

■ Investment ManagementIntegration with Investment Management can be used to budget and accountfor complex tasks in detail.

Personnel Management ■ Personnel ManagementPersonnel Management provides information about the qualifications ofemployees in Asset Lifecycle Management, enabling you to find qualifiedpersonnel for the required maintenance activities.

■ Time ManagementTime Management offers you a uniform, central time-entry tool (CATS -Cross-Application Time Sheet) for internal and external maintenanceemployees and provides shift models for maintenance planning.

General System Functions

Fast Information Using Workflow SAP Business Workflow is a tool you can use to control, manage and therebyoptimize procedures automatically for all stages during the planning andexecution of tasks. Work items are actively written into the worklists forindividuals or organizational units. The user can process the work item directlyfrom their inbox.

Sending Objects Directly You can send many of our objects (for example, equipment, functional locations,notifications or orders) using the object service. The recipient obtains a messagein their inbox, from where they can directly access the object in display mode.

Linking Information to Objects The object link is another extremely useful function for linking PC files (forexample, graphics or texts) to objects, such as equipment or maintenance plans.This means, for example, that you could store a text containing manufacturerinformation about a piece of equipment.


5-3

Simplified ProcessingYou can use Drag&Drop technology, for example, to modify equipment andrelate a piece of equipment to another functional location.

Setting Up Your Own MenuWe also enable you to add your favorites to the menu. You simply choose thetransactions that you use most often and define your own individual menu withDrag&Drop.

No More Static ListsHad enough of static lists? We provide the general list viewer � an ideal tool forstructuring your lists flexibly. Here are just a few examples of our list functions:

■ You can use Drag&Drop technology to shift columns, set the column width,create column totals with interim totals, hide columns or sort according toany criteria. You can even sort according to several fields at the same time(for example, by cost center within an order list and by date within the costcenter).

■ You can download lists onto your PC and edit them using a word processoror spreadsheet program.

■ Our mass processing function can be used to print several orders from anorder list at once.

■ You can also display the breakdown history graphically.

Authorizations � Who Does What?SAP PM also makes assigning authorizations (for example: Who can display aparticular object? Who can change it?) very straightforward. You can organizeauthorizations to suit the individual needs of your company.

Effective Customer ExitsNumerous enhancement options are available to you in Customizing and usingpre-defined customer exits. You can structure SAP PM quickly and cost-effectively, adapting it to the specific business requirements of your company.

Integration with External Systems

The functions available in the SAP application components are supplementedby flexible interfaces to the following external systems:

■ Expert systems for automatic task determinationDifferent tasks are required for different jobs. The tasks can be selectedautomatically during notification processing through the connection of CBR(Condition-Based Reasoning) tools.

■ Laptop systems for supporting field serviceImportant data for processing tasks can be downloaded from the SAP Systemonto a laptop. You can upload completion confirmations back into the SAPSystem.


5-4

Fig. 5-1: Integration with External Systems

■ Systems for Computer-Aided Design (CAD)From engineering and design in the CAD system, you can branch directly tothe maintenance of master data in SAP PM. Conversely, you can display theengineering and design documentation directly in the SAP System.

■ Geographical Information Systems (GIS)In SAP PM or GIS, you can display information about the geographicalposition of objects or create malfunction reports. You can also switch fromone system to the other.

■ External systems for entering measurement and counter readingsYou can transfer data from process control systems or SCADA (SupervisoryControl And Data Acquisition) systems, which describe the condition or useof an object, directly into the SAP System.

■ Systems for Plant Data Collection (PDC)In addition to transferring measurement and counter readings, you can copyinformation for completion confirmations (for example, time confirmationsfor maintenance orders) from PDC systems.

Internet Connection ■ Internet connection for entering measurement and counter readingsYou can enter data that describes the condition or use of an object over theInternet.

■ Internet connection for entering notificationsYou can enter different categories of notifications (for example, malfunctionreports) over the Internet without the need for a direct SAP Systemconnection for each job entered.


5-5

■ Spare parts procurement using external catalogsWhen selecting material components for the order, you can call up directoriesfrom the PC, in which spare parts catalogs are stored. You can also call upthese directories on the Internet, choose the required materials and copy theminto the order.

Optical Storage■ SAP ArchiveLink® for optical storage of incoming documentsYou can assign different documents (for example, photographs of damage,fax of a malfunction report) to tasks and display them directly from the SAPSystem at any time.

In the Field, but in the Know■ Hand-held devicesYou can transmit work-related information from an SAP System to youremployees on a hand-held device (for example, a WAP phone or Palm Pilot).This makes detailed data about the operations required available to theemployee, who can enter materials used, make a technical confirmation andsend the data back to the SAP System.

Range of Functions

6-1

Range of Functions

SAP PM supports you in all the stages of planning and executing maintenancework. The range of functions that we provide includes the following:

Elements of Asset FunctionsLifecycle Management

Functional location / ■ Action logEquipment / ■ AddressesInstalled base / ■ Alternative labelsSerial number / ■ ClassificationObject network ■ Counter readings

■ Counter replacement■ Documents■ Inventory information■ Long text■ Measurement reading transfer■ Measuring points and counters■ Multilingual texts■ Object information■ Partners■ Permits■ Serialization data■ Structure graphic■ Structure list■ Superior locations

Material / ■ Assigned documents / drawingsBill of material ■ BOM comparison

■ Change documents■ Mass change■ Non-stock material■ Plant assignments

Notification ■ Action log■ Activities■ Addresses■ Administration data■ Basic dates■ Causes of damage■ Damage codes

Range of Functions

6-2

■ Documentation of telephone calls■ Document flow■ Note database■ Object information■ Paging / communication■ Partner determination■ Sending confirmations of receipt■ Task determination■ Tasks■ Task simulation

Order ■ Action log■ Addresses■ Budget / commitments■ Completion confirmations■ Components■ Credit limit check■ Delivery addresses of

external material■ Document flow■ Estimated / planned / actual costs■ Execution factor■ External resource management■ Internal processing■ Location■ Material availability■ Network structure / Gantt chart■ Objects■ Operations■ Paging / communication■ Partners■ Permits■ Planning board■ Printing■ Production resources and tools■ Qualifications■ Refurbishment■ Relationships■ Scheduling■ Settlement rule■ Sub-orders■ Task list selection

Range of Functions

6-3

Capacity requirements ■ Available capacityplanning ■ Capacity leveling

■ Capacity requirements■ Evaluation of work centers■ Overload■ Planning board (tabular / graphical)■ Shift sequence

Completion confirmation ■ Collective confirmation■ Error pool■ Individual time confirmation■ Measurement documents■ Overall completion confirmation■ Time sheet

History ■ Document flow■ Historical orders■ Material where-used list■ Notifications■ Operations■ Orders

Maintenance planning ■ Costing (general and object-based)■ Cycle sets■ Deadline monitoring■ Maintenance item■ Maintenance plan■ Maintenance strategy■ Mass change■ Overviews for object, maintenance

plan and operation■ Scheduling■ Scheduling overview■ Task lists

Standard analyses ■ Breakdown analyses■ Cost analyses■ Damage analyses■ Exception analyses■ Location■ Manufacturer■ Object classes■ Object statistics■ Planner groups■ User-defined analyses

Range of Functions

6-4

Elements of Work FunctionsClearance Management

Work approval ■ Catalogs■ Change documents■ Controlling applications■ Controlling orders■ Controlling release for execution■ Documents■ Enhanced approvals■ Location■ Long text■ Object list■ Partners■ Printing

Application ■ Catalogs■ Change documents■ Controlling orders (standard model)■ Controlling release for execution

(standard model)■ Controlling work approvals

(enhanced model)■ Documents■ Enhanced approvals■ Location■ Long text■ Object list■ Partners■ Printing

Range of Functions

6-5

Specifically for work clearance application:

■ Controlling operational workclearance documents

Work clearance document ■ Catalogs■ Change documents■ Documents■ Enhanced approvals■ Locations■ Long text■ Multiple use of tags■ Object list■ Partners■ Printing■ Untagging adjustment

Specifically for work clearance documenttemplate:

■ Library of work clearance documents

Specifically for operational work clearancedocument:

■ Checks, for example, conflict verification■ Controlling operational processes■ Controlling work clearance applications■ Operational protection■ Simulations

Glossary

G-1

Glossary

Asset Lifecycle Management (ALM)Component for organizing and managing technical assets and objects.Asset Lifecycle Management comprises all the areas of a modern EDP-supportedsystem for maintenance management. These areas include, for example,preventive maintenance, inspection plans, catalogs to determine causes ofdamage, spare parts procurement over the Internet, inventorymanagement,shutdown planning and external interfaces to GIS, SCADA and CAD.

EquipmentIndividual, physical object that is to be maintained as an autonomous unit.

Functional locationOrganizational unit that structures the objects of a company to be maintainedaccording to functional, process-oriented or spatial criteria.A functional location represents the place at which a maintenance task is tobe performed.

Lockout/tagoutProcess in which technical objects are isolated electrically or separatedmechanically from other parts of a technical system whilst maintenance workor special tests are performed.The process comprises orderly tagging and subsequent untagging of technicalobjects.Lockout/tagout ensures a safe environment for your maintenance staff inwhich to work and perform controlled tests.

Maintenance bill of materialList used to describe the structure of a technical object and assign spare partsto the object for maintenance purposes.

Maintenance notificationMeans by which internal company notifications are entered and managed inAsset Lifecycle Management.The following standard notification types are available:■ Malfunction report■ Activity report■ Maintenance request

A

E

F

L

M

Glossary

G-2

Maintenance orderMeans of documenting maintenance work. You can use the maintenance order to■ Plan work specifically■ Monitor the execution of work■ Enter and settle the costs incurred by work

The order data is transferred to the maintenance history and is extremelyimportant for evaluations and future planning.

Maintenance planDescription of the inspections and maintenance to be performed onmaintenance objects. The dates and scope of work are also defined here.The following types of maintenance plan are available:■ Single cycle plan (time or performance-based)■ Strategy plans (time or performance-based)■ Multiple counter plan

Maintenance plan schedulingFunction for generating call dates in the maintenance plan. Maintenance callobjects (for example, maintenance orders or service entry sheets) aresubsequently generated for these call dates.Depending on the type of maintenance plan, scheduling can be:■ Time-based■ Performance-based■ Time and performance-based

Maintenance strategyRule for the sequence of planned inspections and preventive maintenance.

A maintenance strategy contains the maintenance packages that define thecycle in which the individual tasks should be performed (for example, every2 months, every 5,000 miles or every 500 operating hours).

It also contains additional scheduling parameters, such as shift factor,preliminary and follow-up buffers, and hierarchy. Maintenance strategies areobligatory in strategy plans. Single cycle plans have only one maintenancecycle, and therefore do not use maintenance strategies.

Glossary

G-3

P

Maintenance task listDescription of a series of individual maintenance activities that are executedrepeatedly in a company.

Maintenance task list is the generic term for all task lists that are used in PlantMaintenance.The following task lists are available■ Equipment task list■ Task list for functional location■ General task list

Measurement documentRecord of a measurement at a measuring point or counter at a particular time.

Measuring pointPhysical or logical place at which a condition is described.Examples:■ Temperature inside a reactor■ Thickness of a vessel wallThe condition is described using measurement readings.Measuring points are managed in the SAP System as master data.

Multiple counter planMaintenance plan that can consists of maintenance cycles with differentdimensions, such as time and distance.You can assign a different counter from a technical object to eachmaintenance cycle. This enables you to define when maintenance is due basedon different dimensions.Example:You can define the interval for an oil change as follows:■ Every 10,000 miles■ Every six months at the latest

Product Lifecycle Management (PLM)Business unit, with which the complete lifecycle of products and technicalassets can be organized and managed. All phases of logistics are integrated intothis e-business solution � from design and production, through sales andmaintenance, to initial investments and finally scrapping of a technical asset.

Glossary

G-4

Refurbishment orderSpecial form of maintenance order that you use when refurbishing re-pairable spares, and for which an order type must be indicated specifi-cally.

You use the refurbishment order to restore a certain number of defec-tive or worn-out repairable spares to full working order again for a par-ticular date.

Single cycle plan

Time or performance-based maintenance plan that you can use tomanage inspections and maintenance to be performed on a referenceobject.

In the single cycle plan, you define one maintenance cycle and the scopeof the maintenance tasks. In contrast to strategy plans, no maintenancestrategies are defined or assigned for a single cycle plan.

Strategy planMaintenance plan with which you can represent complex maintenancecycles using maintenance strategies. For simple maintenance cycles, youuse the single cycle plan, to which no maintenance strategy, only amaintenance cycle is assigned.

Example:A maintenance task should be performed on a reference object every 100,500 or 1,000 operating hours.

R

S

Index

I-1

Index

AActual costs 3-10

ALM See Asset Lifecycle Management;

Analyses 1-8, 4-1, 4-2

For maintenance engineer 2-5, 4-5

For maintenance manager 4-4

For maintenance planner 4-7

For maintenance supervisor 4-8

For technician 4-9

Progress analysis 3-26

Approvals

Work clearance management 3-18

ArchiveLink 5-5

Asset Accounting 5-2

Asset Lifecycle Management 2-1

Complex technical systems 2-4

Function-based 2-1

Installation location and object 2-5

Inventory-managed objects 2-6

Multiple labeling 2-5

Object classification 2-9

Object-based 2-1

Structuring examples 2-2

Structuring options 2-1

Asset Lifecycle Management (ALM) 1-1

Authorizations 5-3

Automobile 2-3

Availability

Technical system 3-10

Availability check

Material 3-8

BBreakdown

Graphical display 5-3

Machine 3-3

Breakdown maintenance 1-6, 3-3

Budget 1-8, 3-9

Building management 2-8

Business completion 3-11

Business content 4-3

Business Information Warehouse (BW) 4-3

BW See Business Information Warehouse

CCAD See Computer-Aided Design

Capacity

Available 3-8

Requirements 3-8

Catalog

Damage 3-6

Internet 5-5

Material 3-9

Cause of damage 3-6, 3-10

CBR See Condition-Based Reasoning

Classification 2-9

Evaluations 2-11

Collective invoice 3-24

Completion 3-10

Business 3-11

Technical 3-11

Completion confirmation 3-10

Final confirmation 3-10

Material 3-10

Partial confirmation 3-10

Technical confirmation 3-10

Computer-Aided Design (CAD) 5-4

Condition-based maintenance 3-14

Condition-Based Reasoning (CBR) 5-3

Controlling 5-2

Corrective maintenance 1-6, 3-4

Cost analysis

Maintenance plan 3-17

Task list 3-17

Costs

Development 3-10

Overview 3-7

Counter reading

Entry on Internet 5-4

External entry 5-4

Counter-based maintenance 3-13

Customer exit 5-3

Index

I-2

DDamage 3-6

Data transfer 3-5

Data warehouse 4-3

Dates 3-6

Dismantling

Repairable spares 3-22

Download

Lists 5-3

EEarly Warning System 1-8

EIS See Executive Information System

Employee roles See Roles

Energy supplier 2-11

Environmental protection

Requirements 3-12

Equipment 2-1

Estimated costs 3-9, 3-10

Evaluations 1-8

Exchange


Executive Information System (EIS) 4-3

Expert system 5-3

External company 3-24

Inspection 3-14

External material 3-9

External resource management 1-7

Simplified form 3-24

With individual purchase order 3-23

With service specifications 3-23

External systems

Integration 2-11

FField service support 5-3

Financial Accounting 5-2

Fleet management 2-3

Functional location 2-1

Key structure 2-4

Requirements of installation location 2-10

GGeneral overhaul 3-25

Geographical Information System

(GIS) 2-11, 5-4

GIS See Geographical Information System

HHand-held devices 5-5

Hazardous substances

Directive on use 3-18

History 1-8, 2-2, 4-4

For serialized objects 2-6

IIndividual invoice 3-24

Individual menu

Set up 5-3

Individual purchase order 3-23

Industrial health and safety measures 3-18

Industry sectors 1-5

Inspection 1-7, 3-1, 3-12

By external company 3-14

Test equipment 3-14

Installation and dismantling


Internet 3-9, 5-4

Catalog 3-9

Intranet 3-9

Inventory management 2-6

Material 3-8

Software 2-7

Investment Management 1-8, 5-2

Invoice

Collective invoice 3-24

Individual invoice 3-24

KKey figures 1-8

LLaptop 5-3

Lifecycle


Index

I-3

Lifecycle management 1-1

Link

Computer-Aided Design (CAD) 5-4

Expert system 5-3

Geographical Information System

(GIS) 5-4

Internet 5-4

Laptop 5-3

PC files 5-2

Plant Data Collection (PDC) 5-4

SAP System 5-1

Supervisory Control And

Data Acquisition (SCADA) 5-4

LIS See Logistics Information System

Lists

Processing 5-3

User-specific view 4-2

Lockout/tagout 1-8, 3-18, 3-19

Logistics Information System (LIS) 4-3

MMachine breakdown 3-3

Mains supply 2-11

Maintenance 3-12

Maintenance engineer

Analyses for 4-5

As role 1-3

Maintenance group 3-8

Employee qualification 3-8

Operating times 3-8

Resources 3-8

Shift schedule 3-8

Maintenance history SeeHistory

Maintenance manager

Analyses for 4-4

As role 1-3

Maintenance notification See Notification

Maintenance order See Order

Maintenance plan

Cost analysis 3-17

Maintenance planner

Analyses for 4-7

As role 1-4

Maintenance process

Overview 3-3

Maintenance supervisor

Analyses for 4-8

As role 1-4

Malfunction frequency

Reduce 3-12

Malfunction report 3-5, 3-7

Management of technical objects

Automobile 2-3

Classified objects 2-9

Complex technical system 2-4

Fleet 2-3

Inventory-based objects 2-6

Mains supply 2-11

Real estate 2-8

Mass processing 5-3

Material

Availability check 3-8


External material 3-9

From Internet catalog 3-9

Inventory-managed 3-8

Planning 3-8

Procurement 1-8

Withdrawal 3-10

Materials Management 3-21, 5-1

Mean Time Between Failures (MTBF) 3-10

Mean Time Between Repairs (MTBR) 3-10

Mean Time To Repair (MTTR) 3-10

Measurement reading

Enter externally 5-4

Enter on Internet 5-4

MTBF See Mean Time Between Failures

MTBR See Mean Time Between Repairs

MTTR See Mean Time To Repair

Multilingualism 1-6

Multiple counter plan 3-14

Multiple labeling 2-5

mySAP.com 5-1

Index

I-4

NNotification 3-5

Create on Internet 5-4

Generate automatically 3-15

OObject history 2-2

Object link 5-2

Operational work clearance document 3-19

Optical storage 5-5

Order 3-6

Actual costs 3-10

Budget 3-9

Business completion 3-11

Capacity requirements planning 3-8

Completion 3-10


Estimated costs 3-9, 3-10

Generate automatically 3-15

Hierarchy 3-7

Maintenance group executing work 3-8

Material withdrawal 3-10

Materials planning 3-8

Permits 3-9

Planned costs 3-10

Printing 3-10

Refurbishment 3-22

Release 3-10

Scheduling 3-8

Shop papers 3-10

Sub-order 3-7

Task list 3-7

Technical completion 3-11

Work steps 3-7

Workflow 3-7

Organizational representation 1-6

Outline agreement 1-8, 3-24

With service specifications 3-23

PPDC See Plant Data Collection

Performance-based maintenance 3-13

Permits 3-9

Personnel Management 5-2

Pervasive computing See Hand-held devices

Planned costs 3-10

Planning 3-6

Plant Data Collection 5-4

Plant Maintenance Information System

(PMIS) 4-2

PLM See Product Lifecycle

PMIS See Plant Maintenance

Information System

Preventive maintenance 1-7, 3-1, 3-12

Condition-based 3-14

Counter-based 3-13

More complex cycle 3-13

Multiple counter plan 3-14

Performance-based 3-13

Scheduling 3-15

Scheduling - FAQs 3-15

Single cycle plan 3-13

Strategy plan 3-13

Time-based 3-13

Procurement


Product Lifecycle Management (PLM) 1-1

Progress analysis 3-26

Project Information System 3-26

Project management 3-25

Project System 3-25, 5-1

Projects 1-8

Purchase requisition 3-23

QQuality assurance 3-12

Quality Management 5-1

RReal estate management 2-8

Refurbishment

Order 3-22


Regulations

Health and safety 3-18

Repair 3-3

Index

I-5

Repairable spares 1-7, 3-21

Exchange 3-21

Installation and dismantling 3-22

Lifecycle 3-21

Procurement 3-21

Refurbishment 3-21

Reporting 4-1

Reports 4-1

Resource planning 3-13

Revision 3-25

Roles 1-3

Maintenance engineer 1-3

Maintenance manager 1-3

Maintenance planner 1-4, 3-18

Maintenance supervisor 1-4

Safety engineer 3-19

Technician 1-4

Work clearance planner 3-19

Work clearance requester 3-19

Rush order 3-3

SSafety at work

Using work clearance management 3-18

Safety check 3-25

SCADA See Supervisory Control And

Data Acquisition

Scheduling 3-8

Automatic 3-15

Backwards 3-8

Forwards 3-8

Frequently asked questions 3-15

Preventive maintenance 3-15

Serial number 2-6

Service 1-8

Service entry sheet 3-24

Service specifications 1-8

Shop papers 3-10

Shutdown 3-25

Single cycle plan 3-13

Solution 3-6

Solution Database 3-6

Exact search 3-6

Fuzzy search 3-6

Solutions 3-6

Symptoms 3-6

Strategy plan 3-13

Sub-order 3-7

Supervisory Control And Data Acquisition

(SCADA) 5-4

Supplier 2-5

Symptom 3-6

TTask

Complex 3-25

Determine automatically 5-3

Document assignment 5-5

With laptop 5-3

Task list 3-7, 3-13

Cost analysis 3-17

Technical completion 3-11

Technical confirmation 3-10

Technical system

Availability 3-10

Modification 3-25, 3-26

New development 3-25, 3-26

Technician

Analyses for 4-9

As role 1-4

Test equipment 5-1

Inspection 3-14

Time confirmation 3-10

Time Management 5-2

Time-based maintenance 3-13

Total Productive Maintenance (TPM) 2-1

TPM See Total Productive Maintenance

UUntagging 3-20

User exit See Customer exit

User orientation 1-3

User roles See Roles

WWork clearance application 3-19

Work clearance document

Operational 3-19

Work clearance management 1-8, 3-18

Object 3-18

Work safety measures 1-8

Workflow 3-7, 5-2

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