plant maint

18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.0200an award winning '2004 Future 50 Company'

Plant Maintenance in SAPA functional perspective

By Gopinath

breaking through barriers to progress

SAP R/3 - Overview

SAP AG

R

Overview: R/3 Overview and Integration

R/3R/3Client / ServerClient / Server

ABAPABAP

COCOControllingControlling

AMAMAsset MgmtAsset Mgmt

PSPSProjectProjectSystemSystem

WFWFWorkflowWorkflow

ISISIndustry Industry SolutionsSolutions

HRHRHumanHuman

ResourcesResources

SDSDSales & Sales &

Distribution Distribution

PPPPProductionProduction

PlanningPlanning

QMQMQualityQualityMgmtMgmt

FIFIFinancialFinancial

AccountingAccounting

PMPMPlant Main-Plant Main-

tenancetenance

MMMMMaterialsMaterials

MgmtMgmt

System-Wide Concepts

TeamSAP AcademyR/3 Overview &

Integration

R/3 Applications

Support & Services

Getting Started

2

3Plant Maintenance - Overview

SAP AG

R

SAP R/3 Modules

Human Resources

Logistics Accounting

Cross ApplicationFunctions

R/3R/3Client / ServerClient / Server

ABAPABAP

FIFIFinancialFinancial

AccountingAccountingCOCO

ControllingControllingTRTR

TreasuryTreasury

PSPSProjectProjectSystemSystem

WFWFWorkflowWorkflow

ISISIndustryIndustry

SolutionsSolutions

MMMMMaterialMaterialManagManag..

HRHRHumanHuman

Resources.Resources.

SDSDSales &Sales &DistribDistrib..

PPPPProductionProductionPlanningPlanning

QMQMQualityQualityManagManag..

PMPMPlantPlant

Maint Maint..


SAP AG

R

SDMM

PP

QAPM

HR

FICO

AM

PSWF

IS

R/3What Is Integration?

Common organizational structures throughoutthe system

Seamless processing of common data betweenapplications

Comprehensive support and reference tools Common reporting features and functionality Object and application linking and overall system

communication


SAP AG 1999

Plant Maintenance is an integral partof the company and has numerouslinks to other enterprise areas.

Depending on the company structure,maintenance planning is either plant-based (decentralized) or cross-plant(centralized).

Organization of Plant Maintenance:Business Scenario


SAP AG 1999

Functional locationsEquipmentAssembliesBills of materialNetworks of technical objects

Maintenance notificationsMaintenance orders

PMIS Plant Maintenance Information System

Maintenance work centers

EQM Technical Data

Task listsMaintenance plans

PRM Preventive Maintenance

WOC Maintenance Processing

CRP Work Centers and Capacity

Structure of Plant Maintenance


SAP AG 1999

Concept of Plant Maintenance

Bills of material

Task lists

CharacteristicsClasses

Equipment /functional locations

Cost recordsCost center

Maintenancework centers

Maintenancenotification

Materialreservation

Materialissues

Maintenanceorder

Capacityload

Timeconfirmation

Purchaserequisition

Maintenancestrategies

Maintenanceplans

Master data

Planning

Order processing

Goods receipt /invoice receipt

Purchase orders /release order


SAP AG 1999

Organizational Structures in Plant Maintenance

General Organizational Units in Logistics

Location-Based Organizational Units

Planning-Based Organizational Units

Maintenance plantFor example, site,building, coordinateFor example, productionarea, plant engineer

Client

Maintenanceplanning plant

Maintenancework centers

For example, foreman,work scheduling

For example, mechanics

Maintenanceplanner groups

Plant section

Location

Plant

Company code


SAP AG 1999

Plant 1000

Cross-Plant Maintenance

Plant 1200 Plant 1300

Workshops

Workshops

Maintenancerequirement


Planning ofmaintenancerequirements


Material

Warehouse

10

Plant Maintenance - Overview

SAP AG 1999

Maintenance Work Centers

Maintenance work centers

For example:Welding

MetalworkingMechanics

11


SAP AG 1999

Work Center: Contents

Basic data General data

Capacity data Capacity categories Scheduling

Capacity / pool capacity

Available capacity profile

T i m e

LinksLinks Activity types

Staffing assignment

Staffing assignment

Activity types

Activity types

Work center

Person

Qualification Staffing assignment

Cost center

12


SAP AG 1999

Work Center: Main Functions

Work CenterWork Center

Costingdata

Costingdata

Default valuesfor task lists and orders

Default valuesfor task lists and orders

Schedulingdata and

available capacity

Schedulingdata and

available capacity

1011

CostingCosting

2,724.001,200.00 124.00

4,048.00

2,724.001,200.00 124.00

4,048.00

Task list / orderTask list / orderLead time

schedulingCapacity planning

Lead timescheduling

Capacity planning

13


SAP AG 1999

Technical

Functional

Spatial

Functional location = multi-level, hierarchical structure, organized according to ...

Criteria

Functional Location

14


SAP AG 1999

Criteria for Functional Locations

Execution of maintenance tasks Recording of maintenance tasks Data collection over long periods

of time Cost monitoring by area What effect do the usage

conditions have on the likelihood of damage to the installed aggregates?

When is a functional location created?

15


SAP AG 1999

Automatic Assignment Upon Creation

C1-BBiologicalcleaning

C1C1ClarificationClarification

plant plantC1-M

Mechanicalcleaning

C1-M01Sandtrap

C1-M02Oil/fattrap

C1-B01Pumpplant

C1-B02Filteringstation

Existingfunctionallocations

Newfunctionallocations

C1-M01-2

VentilatorC1-M01-2Ventilator

C1-M02-2Ventilator

C1-B01-1Pump 1

C1-B02-2Filter cell

16


SAP AG 1999

Example of Functional Location Structure

C1-BBiologicalcleaning

C1C1ClarificationClarification

plant plant

C1-M01-1

Reservoir

C1-M01-2

Ventilator

C1-M01-3Sand

dredger

C1-M02-1

Reservoir

C1-M02-2

Ventilator

C1-M02-3Fat

dredger

C1-B01-1

Pump 1

C1-B01-2

Pump 2

C1-B02-1

Ventilator

C1-B02-2Filtercell

C1-MMechanical

cleaning

C1-M01Sandtrap

C1-B02-1A

Valve 1

C1-B02-1B

Valve 2

C1-B02-2A

Inlet

C1-B02-2BFiltratelevel

C1-B02-2C

Outlet

C1-M02Oil/fattrap

C1-B01Pumpplant

C1-B02Filteringstation

C1-B02-2A/1

Valve 1

C1-B02-2A/2

Valve 2

C1-B02-2C/1

Valve 1

C1-B02-2C/2

Valve 2

17


SAP AG 1999

Criteria for Equipment Master Record

When is a piece of equipment created?

Management of individual data

Recording of maintenance tasks

Object-based recording of costs

Evaluation of technical data

Recording of usage times

18


SAP AG 1999

Equipment Master Record

Equipment master recordEquipment master record

Internal noteInternal note

Documents /Documents /technical drawingstechnical drawings

Multilingual textsMultilingual texts

Equipment usageEquipment usageLocation A

Location B

ClassificationClassificationList

XX

X

XX

XX

Address / partnerAddress / partner

PermitsPermits

Measuring points /Measuring points /counterscounters

0 4 7 10 1 2 3

GeneralGeneral

LocationLocation

OrganizationOrganization

StructureStructure

19


SAP AG 1999

Bills of Material in Company

Engineering/designbill of material

Costingbill of material

Maintenancebill of material

Productionbill of material

20


SAP AG 1999

Breakdown Maintenance: Business Scenario

For breakdown maintenance, thedata required for the other businessprocesses needs to entered quicklyand easily so that the subsequentsteps can be executed.

21


SAP AG 1999

NotificationNotification

PlanningPlanning

SchedulingScheduling

ExecutionExecution

CompletionCompletion

History Material usage, orders, notifications, PMIS, usage list


Technical object Description

Date Malfunction

Work to be performed Internal/external resources

Material Tools

Capacity leveling Availability check

Order release Printout

Planned/unplanned material withdrawal External procurement

1

44

55

22

33

1

22

33

Business Process: Breakdown Maintenance

Time confirmation Technical completion

Order settlement Technical confirmation

22


SAP AG 1999

Maintenance Order: Putting in Process

Status'RELEASED'

Order papersPut in process

23


SAP AG 1999

Time Confirmations

Initial screen

Partial confirmationFinal confirmation

Reversal option

Scope

Individual entryCollective entryCollective entry using operation listOverall completion confirmation

24


SAP AG 1999

Maintenance Order: Technical Completion

Order 901760

Limited ability to change order

Status 'Technically completed'

Define location and account assignment data

Create settlement rule

Set deletion flag for purchase requisitions

Close open reservations

Close open capacities

25


SAP AG 1999

Notification

Planning

Scheduling

Execution

Completion



Date Malfunction


Material Tools






4

5

2

3

1

Cycle for Corrective Maintenance

26


SAP AG 1999

Describes the condition of a maintenance object,particularly a malfunction

Describes a maintenance activity already performed(purely technical documentation)

Requests a maintenance service/task

Malfunction report

Activity report

Maintenance request

Definition of Maintenance Notification

27


SAP AG 1999

Date / time / reported byDescriptionObject: Functional location Equipment Assembly

Material serial numberLocation dataBreakdown / availability

Activity Execution factorsActivities

Dates Task descriptionTasks

Damage location Damage Cause of damage

TextNotificationitems

Notification

Maintenance Notification: Structure

28


SAP AG 1999

iiObject information

NotificationsMaintenance dates

Documents

Links

Breakdowns

Structure list

Processing days

Orders

Maintenance Notification: Object Information

29


SAP AG 1999

Select Maintenance Notifications

Find particular maintenance notificationProcess several maintenancenotifications simultaneouslyRestrict planning worklist

Why ?

Different sortingSelect / delete complete listDifferent list fields, internal display variantDisplay breakdowns graphicallyExcel processing

Scope

Selection conditionsField selection

Customizing

Functions

NotificationNotification itemsTasks

30


SAP AG 1999

Print Maintenance Notifications

Maintenancenotification

Notificationoverview

Breakdownreport

Activityreport

Fax transfer

31


SAP AG 1999

Notification

Scheduling

Execution

Completion



Date Malfunction






4

5

3

1

PlanningPlanning Work to be performed Internal/external resources

Material Tools

2


32


SAP AG 1999

Maintenance order / notificationDirect creationof order

Maintenance notification

Maintenance order

Creation of orderbased on notification

Maintenance item

Maintenance order

Automatic generation ofmaintenance orderfrom maintenance item




Maintenance order

Combination of maintenance notificationsfor maintenance order


Maintenance order

Entry of order withsubsequent activity report

Creation of Maintenance Orders

33


SAP AG 1999

Flexibility of order processing

Execution

Period of validity

Object referenceSingle object Object list

Single order Standing order

Internal processing External processing

Characteristics of Maintenance Orders

34


SAP AG 1999

Componentassignment

Materialreservation

MayMayAvailabilitycheck

Goodsissue

Printing

Orderrelease

Automaticavailabilitycheck MayMay

Stock Material - Process Flow

35


SAP AG 1999

Notification

Planning

Execution

Completion



Material Tools



Date Malfunction



4

5

2

1

SchedulingScheduling Capacity leveling Availability check


33


36


SAP AG 1999

Stockprofile

Inward stockmovementfrom purchaseorder

Material withdrawalfor cost center

Inward stock movementfrom internal production

Stock transferto other plant

Plantstock

Today Requirement date

Safetystock

MaximumATP quantity

Resource Planning: Availability Check

37


SAP AG 1999

Maintenanceorder Fax transfer

Job ticket

Operation control ticket

Pick list

Materialwithdrawal

slip

Confirmationslip

Time ticket

Object list

Maintenance Order: Printing

38


SAP AG 1999

TimesIndividual entryCollective entryOverall completion confirmationTime sheet (CATS)

ActivitiesActivity reportsOverall completion confirmationConfirmation texts

Object changes

Measurement readings

Order Completion Confirmation: Times / Activities

39


Questions ??

Contact Details :

mail id : [email protected]

Cell : 469-879-4674

Residence : 972-444-8510

plant maint

Documents

companyplant maintenance

maintenance planning

organizational unitsplanning

coordinatefor example

work schedulingfor ex

company structure

functionality object

award winning