plant maint

18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.0200

an award winning '2004 Future 50 Company'

Plant Maintenance in SAP

A 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

3

Plant Maintenance - Overview

SAP AG

R

SAP R/3 Modules

Human Resources

Logistics Accounting

Cross ApplicationFunctions

R/3R/3Client / ServerClient / Server

ABAPABAP

FIFIFinancialFinancial

AccountingAccounting

COCOControllingControlling

TRTRTreasuryTreasury

PSPSProjectProjectSystemSystem

WFWFWorkflowWorkflow

ISISIndustryIndustry

SolutionsSolutions

MMMMMaterialMaterialManagManag..

HRHRHumanHuman

Resources.Resources.

SDSDSales &Sales &DistribDistrib..

PPPPProductionProductionPlanningPlanning

QMQMQualityQualityManagManag..

PMPMPlantPlant

Maint Maint..

4


SAP AG

R

SD

MM

PP

QA

PM

HR

FI

CO

AM

PS

WF

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 systemcommunication

5


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

6


SAP AG 1999

Functional locations

Equipment

Assemblies

Bills of material

Networks of technical objects

Maintenance notifications

Maintenance orders

PMIS Plant Maintenance Information System

Maintenance work centers

EQM Technical Data

Task lists

Maintenance plans

PRM Preventive Maintenance

WOC Maintenance Processing

CRP Work Centers and Capacity

Structure of Plant Maintenance

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SAP AG 1999

Concept of Plant Maintenance

Bills of material

Task lists

Characteristics

Classes

Equipment /functional locations

Cost records

Cost center

Maintenancework centers

Maintenance

notification

Materialreservation

Materialissues

Maintenanceorder

Capacityload

Timeconfirmation

Purchaserequisition

Maintenancestrategies

Maintenance

plans

Master data

Planning

Order processing

Goods receipt /invoice receipt

Purchase orders /release order

8


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, coordinate

For example, productionarea, plant engineer

Client

Maintenance

planning plant

Maintenancework centers

For example, foreman,work scheduling

For example, mechanics

Maintenance

planner groups

Plant section

Location

Plant

Company code

9


SAP AG 1999

Plant 1000

Cross-Plant Maintenance

Plant 1200 Plant 1300

Workshops

Workshops

Maintenance

requirement

Maintenance

requirement

Planning of

maintenance

requirements

Maintenance

requirement

Material

Warehouse

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SAP AG 1999

Maintenance Work Centers

Maintenance work centers

For example:Welding

MetalworkingMechanics

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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

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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

2,724.00

1,200.00

124.00

4,048.00

2,724.00

1,200.00

124.00

4,048.00

Task list / orderTask list / orderLead time

schedulingCapacity planning

Lead timescheduling

Capacity planning

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SAP AG 1999

Technical

Functional

Spatial

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

Criteria

Functional Location

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SAP AG 1999

Criteria for Functional Locations

� Execution of maintenance tasks� Recording of maintenance tasks

� Data collection over long periodsof 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?

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SAP AG 1999

Automatic Assignment Upon Creation

C1-BBiologicalcleaning

C1C1

ClarificationClarification

plant plant

C1-MMechanical

cleaning

C1-M01Sandtrap

C1-M02Oil/fattrap

C1-B01Pumpplant

C1-B02Filteringstation

Existingfunctionallocations

Newfunctionallocations

C1-M01-2

Ventilator

C1-M01-2Ventilator

C1-M02-2Ventilator

C1-B01-1Pump 1

C1-B02-2Filter cell

16


SAP AG 1999

Example of Functional Location Structure

C1-BBiologicalcleaning

C1C1

ClarificationClarification

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

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SAP AG 1999

Equipment Master Record

Equipment master recordEquipment master record

Internal noteInternal note

Documents /Documents /technical drawingstechnical drawings

Multilingual textsMultilingual texts

Equipment usageEquipment usage

Location A

Location B

ClassificationClassificationList

XX

X

X

X

XX

Address / partnerAddress / partner

PermitsPermits

Measuring points /Measuring points /counterscounters

0 4 7 10 1 2 3

GeneralGeneral

LocationLocation

OrganizationOrganization

StructureStructure

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SAP AG 1999

Bills of Material in Company

Engineering/designbill of material

Costingbill of material

Maintenancebill of material

Productionbill of material

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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.

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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

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SAP AG 1999

Maintenance Order: Putting in Process

Status

'RELEASED'

Order papers

Put in process

23


SAP AG 1999

Time Confirmations

Initial screen

Partial confirmation

Final confirmation

Reversal option

Scope

Individual entryCollective entry

Collective entry using operation list

Overall completion confirmation

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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

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SAP AG 1999

Notification

Planning

Scheduling

Execution

Completion



• Description

• Date

• Malfunction








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 by

DescriptionObject: Functional location

Equipment Assembly

Material serial numberLocation data

Breakdown / availability

Activity

Execution factorsActivities

Dates Task description

Tasks

Damage location

Damage

Cause of damage

TextNotification

items

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 maintenance

notifications simultaneouslyRestrict planning worklist

Why ?

Different sortingSelect / delete complete list

Different list fields, internal display variantDisplay breakdowns graphically

Excel processing

Scope

Selection conditions

Field selection

Customizing

Functions

Notification

Notification items

Tasks

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SAP AG 1999

Print Maintenance Notifications

Maintenancenotification

Notificationoverview

Breakdown

report

Activityreport

Fax transfer

31


SAP AG 1999

Notification

Scheduling

Execution

Completion



• Description• Date

• Malfunction






4

5

3

1

PlanningPlanning • Work to be performed• Internal/external resources


2


32


SAP AG 1999

Maintenance order / notificationDirect creationof order

Maintenance notification

Maintenance order

Creation of order

based on notification

Maintenance item

Maintenance order

Automatic generation ofmaintenance orderfrom maintenance item




Maintenance order

Combination of maintenance notifications

for 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 reference

Single object

Object list

Single order

Standing order

Internal processing

External processing

Characteristics of Maintenance Orders

34


SAP AG 1999

Component

assignment

Material

reservation

MayMay

Availability

check

Goods

issue

Printing

Order

release

Automatic

availabilitycheck MayMay

Stock Material - Process Flow

35


SAP AG 1999

Notification

Planning

Execution

Completion






• Description

• Date

• Malfunction



4

5

2

1

SchedulingScheduling • Capacity leveling

• Availability check

• Order release

• Printout33


36


SAP AG 1999

Stockprofile

Inward stock

movement

from purchaseorder

Material withdrawalfor cost center

Inward stock movementfrom internal production

Stock transfer

to other plant

Plant

stock

Today Requirement date

Safety

stock

MaximumATP quantity

Resource Planning: Availability Check

37


SAP AG 1999

Maintenanceorder

Fax transfer

Job ticket

Operation control ticket

Pick list

Material

withdrawal

slip

Confirmation

slip

Time ticket

Object list

Maintenance Order: Printing

38


SAP AG 1999

TimesIndividual entry

Collective entryOverall completion confirmation

Time sheet (CATS)

ActivitiesActivity reports

Overall 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

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