sap plant maintenance - notes.docx

7/30/2019 SAP Plant Maintenance - Notes.docx

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SAP Plant Maintenance

Plant Maintenance

All actions necessary for retaining an item, or restoring to it, a serviceable condition, includeservicing, repair, modification, overhaul, inspection and condition verification

Increase availability of a system Keep systems equipment in working order

Purpose of Maintenance

Attempt to maximize performance of production equipment efficiently and regularly Prevent breakdown or failures Minimize production loss from failures Increase reliability of the operating systems

Principle Objectives in Maintenance

To achieve product quality and customer satisfaction through adjusted and serviced equipment Maximize useful life of equipment Keep equipment safe and prevent safety hazards Minimize frequency and severity of interruptions Maximize production capacity through high utilization of facility

Maintenance Objectives

Must be consistent with the goals of production (cost, quality, delivery, safety) Must be comprehensive and include specific responsibilities

Maintenance Costs

Cost to replace or repair

Losses of output Delayed shipment Scrap and rework

Types of Maintenance


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Maintenance may be classified into four categories: (some authors prefer three categories- scheduled and preventive maintenances are merged) Corrective or Breakdown maintenance Scheduled maintenance Preventive maintenance Predictive (Condition-based) maintenance

Corrective or Breakdown Maintenance

Corrective or Breakdown maintenance implies that repairs are made after the equipment isfailed and can not perform its normal function anymore

Quite justified in small factories where: Down times are non-critical and repair costs are less than other type of maintenance Financial justification for scheduling are not felt

Disadvantages of Corrective Maintenance

Breakdown generally occurs inappropriate times leading to poor and hurried maintenance Excessive delay in production & reduces output Faster plant deterioration Increases chances of accidents and less safety for both workers and machines More spoilt materials Direct loss of profit Can not be employed for equipments regulated by statutory provisions e.g. cranes, lift and

hoists etc

Scheduled Maintenance

Scheduled maintenance is a stitch-in-time procedure and incorporates inspection lubrication


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repair and overhaul of equipments If neglected can result in breakdown Generally followed for:

overhauling of machines changing of heavy equipment oils cleaning of water and other tanks etc.

Preventive Maintenance (PM)

PrinciplePrevention is better than cure Procedure - Stitch-in-time It

locates weak spots of machinery and equipments provides them periodic/scheduled inspections and minor repairs to reduce the danger

of unanticipated breakdowns

Advantages of PM

Advantages: Reduces break down and thereby down time Lass odd-time repair and reduces over time of crews Greater safety of workers Lower maintenance and repair costs Less stand-by equipments and spare parts Better product quality and fewer reworks and scraps Increases plant life Increases chances to get production incentive bonus

Predictive (Condition-based) Maintenance

In predictive maintenance, machinery conditions are periodically monitored and this enables themaintenance crews to take timely actions, such as machine adjustment, repair or overhaul


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It makes use of human sense and other sensitive instruments, such as audio gauge, vibration analyzer, amplitude meter, pressure, temperature and resistance

strain gauges etc.

Unusual sounds coming out of a rotating equipment predicts a trouble An excessively hot electric cable predicts a trouble Simple hand touch can point out many unusual equipment conditions and thus predicts a

trouble

Maintenance data in IDB

Tables contains Maintenance data in IDB

S.No Table Name Description

1 IBIPMPLA Plan Contains Plans for each PrimaryEquipments

2 IBIPMPOS ItemContains item for respective Primary

equipments

3 IBIPOLST Object List

Contains equipments if an item

includes more than one unique

equipments

4 IBIPTLOP Task List Operation

Contains task list operations for each

task. Task to be carried out at different

intervals 1M, 6M, 1Y, 2Y, 4Y,.. 1W,2W..

5 IBIPTLST Task List Contains tasks for each item

6 IPIBTEXT Standard Text Contains standard text / PM routinesfor each task list operation

Related tables used for reference

S.No Table Name Description

1 IBIP_PMEQM Functional Locations + Equipments

2 SAP Reference Tables SAP Reference Tables

Relationship between Tables


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Notes

Analyze equipments list in PMEQM and identify maintainable group and maintainable itemfor PM / SD Plans

Generally, maintenance plan is created based on Vendor recommendation given in vendormanual (Instruction & operating manual or Instruction & Maintenance manual). Refer

Troubleshooting

All plans are prepared based on equipment criticality. If equipment is low critical then Plan isnot required for such equipment.

Use existing strategies to assign task for maintainable item. If there is no task for anparticular equipment then Plan, item and task not required as per the existing strategies

Check availability of Existing Plan, Item & Task When checking existing Task, check number of equipments given as G2, G3, G4, G6 in task

description.

- Use task header (planner group) and group counter if item contains the same numberof equipments otherwise create new group counter for such item.

- Usually new group counter is next sequence number of existing- If we use existing task and group counter, Work center should be matched otherwise

create new group counter

- Duration (Man hour), Work details are available in existing task list operation.- Group counter to be checked against Item suppression.- Work = Duration x Man power (No. of required capacity)

Analyze Task list for the maintainable items is General or Equipment Task list General task list is used in PM plan & Items


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Equipment task list is used in SD Plan & Items Maintenance for most of the static equipments are shutdown (SD) Some of the equipments have both PM and SD. The equipments like SDV, Control Valves,

ESDV, MOV, XV etc.,

Check CM and INSP maintenance is applicable All the the items in the particular plan should be have same strategy either Monthly or

Weekly

CM If existing Plan & item used commonly for maintenance Planning plant like Fire zonethen in item table, populate maintenance planning plant(KMDS,NGL2..) in functional location

and object list table BAUTL should be maintenance planning plant(KMDS,NGL2..)

sap plant maintenance - notes.docx

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