November 2010Key Issues in Industries (Maintenance) - Plant Maintenance
Long lead time to repair because of long mobilization time. This also results in a significant number of maintenance jobs tilting towards emergency maintenance.
Poor planning because of lack of integration with human resources data . This results in idle skills and manpower in some cases and overloaded manpower and skills in others
Mismanaged parts inventory resulting in high or low availability of parts
A large number of companies are not only experiencing increasing maintenance costs but are also experiencing increasing downtime costs that outstrip direct maintenance costs by a significant proportion.
Incomplete equipment/asset structures
Unclear on set up of Maintenance Plans for single equipment, complex equipment/system or inspection routes 
Poor communication of equipment/system problems
Lack of visibility across multiple activities and entities in more than one plant/location.
Complexity of the plant maintenance system and tasks performed result in increased labor costs.
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Plant Maintenance
New Regulations and Compliance
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SAP Plant Maintenance provide a flexible Plant Maintenance system with easy access and adaptability to allow better coordination amongst shop floor engineers and supervisors.
Reduce unplanned (breakdown) work order by having access to real-time data through SharePoint or mobile technology, thus moving from a reactive to a more proactive mode.
Provide a mobile infrastructure so that employees can move effectively across multiple plants and locations reducing non-value added work and increasing productivity.
Improved overall work identification quality using SAP Notifications to capture all work within the System, with well-defined standards that enabled clear communication of equipment problems/symptoms custom reports that allowed for better workload management, KPI-reporting and trending.
SAP PM Established a comprehensive scheduling methodology to work seamlessly with the SAP scheduling transactions to publish schedules weekly.
Reduced Cost - Increased labor utilization with advanced scheduling and planning tools ,Do the right jobs with prioritization. Execute efficiently with work instructions and parts planning
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SAP Plant Maintenance Introduction
SAP Plant Maintenance automates the process of performing facility repair and maintenance requests.
For example,. SAP records a problem that is reported, labor and materials are planned, costs are recorded, and then costs are settled
Plant Maintenance operates the overall maintenance business processes and functions allows a maintenance organization to:
Identify, document, and correct failures and degradations of any assets for which they have responsibility.
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Customer Service – Warranty Processing
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Break Down Maintenance
Break Down Maintenance
Using this business process we can report, perform, and document maintenance tasks that arise suddenly.
All the resources used, costs, and technical details of the maintenance task are recorded centrally and can then be evaluated.
Usually this process is relevant if a technical asset exhibits a defect, for example, if a pump is leaking or a printer is not printing properly.
Diverse employees can create a maintenance notification to report the defect.
The responsible maintenance technician receives these notifications in his or her work list and makes the necessary repairs.
Process Flow
1.Notification & Scheduling
2. Execution
3. Completion
Preventive maintenance work is performed to ensure optimal operation of equipment & avoid costly unplanned equipment failure or shutdown.
To keep down times and maintenance costs minimum, the technical systems are inspected and maintained regularly
Preventive Maintenance Can be followed by 3 Factors
Time Based
Performance Based
Condition based
Time Based
In time-based preventive maintenance, the maintenance tasks are planned and performed depending on the time-dependent intervals determined. (Ex ,Every 6 months)
Performance-Based (Performance)
This preventive maintenance, tasks are triggered after a specific performance level has been reached
(Ex, Every 10,000 kms)
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Preventive Maintenance
Preventive Maintenance
Condition Based
 If the service life is exhausted or if the asset is no longer in good enough condition to perform its service to the required quality
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Corrective Maintenance
Corrective Maintenance
Maintenance actions carried out to restore a defective item to a specified condition
5 Phases of corrective Maintenance
Entering Requirement(Notification)
Monitoring the cost (Control)
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Notification: is the technical object contains the description about the malfunction or requirement
Malfunctions and other requirements are recorded in notification, notifications can be accessed and processed via a list
Planning : In this phase orders are created and planned on the basis of the reported requirements. Planning compasses the Work to be performed , and the material required.
Control: In this phase order runs through the different phases such as material availability check, capacity planning.
Execution: Order is executed in this phase, Required material for the order is withdrawn.
Completion: Technical Conformation and Technical completion.
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Refurbishment Of Spare Parts
Refurbishment of spare parts:
In a company ,Defective or warn-out spare parts in storage should be refurbished.
Refurbishment Process
Separate Evaluation
Refurbishment Order
Check the effects of refurbishments on stock value
Calculate the time and material resources are needed for the refurbishment.
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Work Clearance Management
Work Clearance Management
This business process to enforce all safety measures that must be enforced before inspections, repairs, or preventive maintenance work are performed.
Maintenance Workers operate in a dangerous Environment(Ex: High Voltage, Radio Activity).
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Work Clearance Management
Work Clearance Management
Lockout-Tag out (LOTO) or lock and tag is a safety procedure which is used to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work
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Customer Service – Service Planning
Capacity requirements planning supports you in the detailed resource planning of technicians in Customer Service.
You can only use this component in connection with the following application components:
Service Orders (CS-SE)
Maintenance Planning consists of -
Maintenance item - A maintenance item describes which preventive maintenance tasks should take place regularly on a technical object or a group of technical objects.
Maintenance Plan - The maintenance plan contains scheduling information from the following sources
Maintenance Strategy - A maintenance strategy defines the rules for the sequence of planned maintenance work
Maintenance cycle - The maintenance cycles and packages contain the time or performance condition when maintenance must be performed
Scheduling parameters - use the scheduling parameters to adapt the scheduling process to meet your individual requirements.
Maintenance Task list - Maintenance task lists describe a sequence of individual maintenance activities which must be performed repeatedly within a company
Maintenance Objects - A list of objects which are assigned to a particular maintenance item.
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AMCs: Annual Maintenance Contract once the warranty gets over – Comprehensive
Non – Comprehensive AMC : Only certain parts are covered under the contract
Only Parts Covered
Only Labor Covered
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Customer Service – Warranty Processing
The warranty check can be performed automatically by the system when processing customer notifications and billing requests
The Customer Service component provides the following types of warranty:
Time-bound warranties
Counter-dependent warranties
Warranties that are valid for periods of time and counter intervals.
Types of Warranty
Warranty & Free Services – Free Services provided against Warranty to Customer.
After Sales Service – Services provided after the Warranty period is surpassed or Warranty voids.
Retro fitment Services – provided for a particular defect in some Lot of vehicles.
Annual Maintenance Contracts are also created for Corporate Clients with Proper Servicing Schedules for the technical object.
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Benefits to Clients on SAP PM Implementation
The equipment history is ON-LINE. You can access information from any of the client locations at any point of time, hence this reduces the time to get information and reduces the time to make a decision for any critical situation.
All maintenance activities are online, like maintenance plans for the entire year, All equipment of entire organization.
The cost involved for the maintenance activities are available online, so no need of any MIS reports at every month.
Good integration with Materials for receiving the material for the maintenance activities from stores.
Easy tracking of malfunctioning, breakdown and tracking down maintenance activities.
You can maintain the equipment log sheet online. like boiler temp reading etc....
. You can integrate with Quality module and monitor calibration maintenance.
You can have permits online instead of having on paper and roaming to the depts. to get the permit.
Maintenance costs are lowered
Resource efficiency is improved.
Improved prioritizing, planning, and executing activities aligned to corporate strategy and more readily provide the right resources at the right time from the right source required for execution
Lowered operating costs and capital expenditures
Plant Section