02_SAP PM Plant Maintenance Universal Process Model

(1)

SAP – PM End User’s Training

Plant Maintenance

(2)

Plant Maintenance

Universal Process Model (UPM)

Asset Management Structure

Asset Maintenance Management

Conduct budget control

Perform intercompany spare parts sales Measuring Point (PM & Fleet)

Project execution for assets

Conduct order managed modifications Install capital equipment

Dismantle equipment

Preventive / Predictive Maintenance

Perform preventive / predictive maintenance

Corrective maintenance

Conduct unplanned/emergency breakdown maintenance Perform low cost repairs

Perform Planned Repairs Refurbish spare parts

(3)

Asset Management Processes

• Broken up into 4 Core Process Functions

– 1) Asset Maintenance Management

– 2) Execute Projects for assets

– 3) Preventive/Predictive Maintenance

– 4) Corrective Maintenance

Asset Management Asset Maintenance Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance

(4)

Asset Maintenance Management

• Conduct Budget Control

– Depending on the implementation within the company, budgetary control measures can be set up at cost center level or for the

maintenance order itself. At individual

maintenance order level, a budget can be set and once the budget has been reached, no more costs can be accumulated against that order. The budget can be changed with the necessary authorization

• Perform Intercompany Spare Parts Sales -

– Within R/3, the stock of spare parts can be

viewed across plants. It is however, important to ensure that there is standardization

relating to the relevant master data of the parts.

• Measuring Point (PM & Fleet) -

– measurement documents are created against the assets that allow for follow up activities in invoicing and managing fuel usage against distance incurred (Fleet)

Asset Management Asset Maintenance Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Conduct Budget Control Perform Interco. Spares Sales Measuring Points (PM & Fleet)

(5)

• Conduct Order Managed Modifications -

– A modification to equipment is made to

improve its performance or to prolong its usable life. This is a planned intervention, for which a cost estimate and approval is

required. This process adds value back to the asset.

• Install

Capital Equipment -

– Maintenance departments are commonly used to assist with the installation of Capital Equipment. This process describes the use of the Maintenance Order to procure the

equipment and the settle it to WBS elements and the settlement of the labor to expense cost elements.

• Dismantle Equipment -

– Within Capital Projects, an expense portion can exist in the dismantling or demolition of the equipment. This process make use of the Maintenance Order to accomplish. It also triggers the need for asset disposition and changes to functional location structures

Asset Management Asset Management Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Conduct Order Managed Modifications Install Capital Equipment Dismantle Capital Equipment

(6)

Preventive/Predictive Maintenance

• Perform Preventive/Predictive Maintenance

– Process allows for the development of

routine and repetitive pre-scheduled

maintenance activities

• Support Reliability Principles

• Support Operational Excellence

Methodologies

• Flexible for PM Optimization

activities

• Flexible to institutionalize PMs based

upon COE Successful Practices

• Options for Time Based, Performance

Based, and Condition Based PMs

available

• Can be set to single cycle,

multi-cycle, or a combination of both

• Can be used to manage EOSH routine

activities

Asset Management Asset Management Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Preventive/ Predictive Maintenance

(7)

Corrective Maintenance

Processes support both Reactive and Proactive Corrective Maintenance activities:

Perform Emergency Repairs -

o In this process the steps before completion of the work are minimized so efforts go towards resolving

issues associated with the emergency. After completion of the repair, history is then gathered.

Perform Low Cost Repairs -

o In this process, a standing order is created to capture confirmed activities to repair minor stops and

short duration fixes.

Perform Planned Repairs -

o Newly created to enable and institutionalize the COE’s best practice Proactive Maintenance Planning and Scheduling processes

Refurbish Spare Parts w/Split Valuation -

o This process deal with the refurbishment of - usually high value - faulty repairable spares. This is of

considerable economic importance for our bottlers and is often a core process in Plant Maintenance. It is often much more cost-effective than a brand new purchase.

Reactiv

e

Pr

oact

iv

e

Asset Management Asset Management Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Perform Emergency Repairs Perform Low Cost Repairs Perform Planned Repairs Refurbish Spare Parts

(8)

Asset Management

• These 4 Core Process Functions, Asset Maintenance Management, Execute Projects,

Preventive/Predictive Maintenance, & Corrective Maintenance, now provides us the Asset

Visibility to:

1. Reduce Operating Cost by improv

ing Labor utilization

2. Reduce Operating Cost by better managing parts and services

3. Reduce the Asset swell in spare parts by better management locally, regionally, and

globally, bring down unproductive inventory values

4. Reduce spend on spare parts procurement

5. Reduce the need to procure more capital

6. Focus on key Assets that provide the best opportunity to add availability and capacity

without adding capital

7. Increase Efficiency’s

8. Increase Throughput

9. Reduce other Supply Chain costs

10. Ultimately improve the Return on Assets involved in the Make Process of Finished

Goods

Asset Management Asset Maintenance Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance

(9)

Plant Maintenance

Technical & Object data

(10)

Required Organizational Entities

10 10

According the Systems Applications and Products (SAP) standard organizational objects, the business

scenario is mapped as follows:

General organization

Location-based organization

Planning-based organization

(i.e. oil & gas company)

(11)

Required Organizational Entities

Company Codes

• Company codes generally represent the various legal entities within an organization. The Company Code is

the lowest level for which you can produce a complete set of financial reports.

• There is no PM configuration in this area.

Plants

• In the Enterprise Resource Planning (ERP) System, the plant is a place of work or a branch within a

company. The plant is integrated in the organizational structure as follows

 One plant (i.e. plant -0001) is assigned to exactly one company code (i.e. Company - 1000). One company code can have several plants.

 One plant can have several storage locations at which materials stocks are stored  Exactly one business area is assigned to a plant and a division

 A maintenance plant can be defined as a planning plant

• A plant has the following attributes:

 It has an address.

 It has a language.

 It belongs to a particular country.

 It has its own material master data.

.

(12)

Required Organizational Entities

Maintenance plants and planning plants

• The maintenance plant of a technical object is

the plant in which the object is installed.

• The planning plant of a technical object is the

plant in which the maintenance tasks for that

object are planned and prepared.

 Planner groups is part of the planning

plant which prepare a tasks for the

technical object in maintenance plants

(13)

Required Organizational Entities

Planner Groups

• Planner Groups are also organizational structure units. This is typically localized, but customization and logic to other functions such as notification screens and printing uses standard Planner Groups for PM to provide added functionality.

• The below have been set up in the system to be maintained .

• Planner groups can move to being plant specific because of segregation from CAM

Work Centers

• Work Center (Location Tab) is defined as an

organizational unit that assigns where the technical object is located.

• This is the Production Planner (PP) Work Center and not the Maintenance Work Center which is usually associated to labor.

• Where possible in Equipment Record and Functional Location Record this field should be populated. This require obtaining the PP Work Center information for populating this information in advance or as a

dependency during load.

(14)

Required Organizational Entities

Storage Locations

• The Storage Location is defined as an organizational unit, allowing for differentiating between the

various stocks of a material in a plant.

• Specified amounts of materials can be moved between different storage locations.

• A Storage Location is typically represented by a plant-unique 4-digit alpha-numeric.

• Material stocks can be differentiated, on a quantity basis, within one plant according to storage

location.

• Storage locations are always created for a plant. • Physical inventories are carried out at storage

location level.

• For Coke One, common storage locations have been set up for each plant.

Plant Section

• Plant Section is generally considered a local

organizational unit. It is used to further breakdown a

Maintenance Plant into physical or logical functions. • Guidance is given in this area as the Plant Section is also

used in the Functional Location structure to provide consistency in analysis of various plants in the BIG. • There is no straight forward way to standardize this

organizational unit as each plant has its own unique differences and configuration. The below provides guidance to selecting the Plant Section number.

 010 – 019 General Plant Services, Building & Grounds

 020 – 029 Bottle /Can Sorting & Delivery Systems

 030 – 039 Blending & Mixing Production & Packaging

 040 – 049 Production & Packaging

 050 – 059 Warehousing and Logistics

 060 – 069 Trade Services

 070 – 079 Fleet

 080 – 089 Office & Support Functions

 090 – 099 Redeployable Asset

(15)

Required Data Elements - Functional Location

• The structure indicator of a functional location determines the structure of the functional location label. It establishes the following factors:

 Number of hierarchy levels of a technical system  Key length of the levels

 Separators (hyphens)

• For Coke One, the Structure Indicator is ZSTD. The edit mask assigned to it is:

NNNN-NNN-NN-NNN-NNNNN

NNNN = Plant Code (i.e., 0000 = Singapore’s Plant Number) Spatial

NNN = Plant Section (i.e., 010 = Manufacturing Bldg) Spatial and Process-based NN = Type of Line or Process (i.e., 01 = Production Area) Process-based

NNN = Plant Line # or Plant Process# (i.e., 001 = Line 1) Spatial NNNNN = Equipment /System Function (i.e., 00100 = Filler) Functional

Example above = 0001-010-01-001-00100

(16)

Perform Preventive Predictive Maintenance -

Master Data

SAP – Technical & Object data & base requirement

1. Work Center List Display (CR05)

2. Functional Location Structure Display (IH01)

3. Equipment List Display (IE03)

4. Function location master data Display (IL03)

5. Equipment master data Display

(17)

Asset Maintenance

Management

Asset Management

Asset Maintenance Management Conduct budget control

Perform intercompany spare parts sales Measuring point (PM & Fleet)

Dismantle equipment

Conduct emergency breakdown maintenance Perform low cost repairs

Asset Management Asset Maintenance Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Conduct Budget Control Perform Interco. Spares Sales Measuring Points (PM & Fleet)

(18)

18

Measuring Points and Counters

A Measuring point is Master Data created for a Technical Object in order to document a Measurement or a Counter reading. This is done for one of three reasons:

You want to document the condition of a technical object at a particular point in time.

You want to perform Counter Based Maintenance (Preventive).

You want to perform Conditioned Based Maintenance (Predictive).

In the case of Counter Based Maintenance, maintenance activities are scheduled to be performed when the Counter of the Technical Object has reached a particular Counter

Reading, for example, every 100 Operating Hours.

In the case of Condition Based Maintenance, maintenance activities are scheduled to be performed when the Measuring Point of a Technical Object has reached a particular state, for example, every time a brake pad has been worn away to the minimum thickness permitted, or when the cooling water for a Nuclear Power Plant exceeds the upper limit allowed.

The Measuring Point must have a Characteristic assigned to it.

(19)

Fleet Measuring Point (KM & Fuel Consumption

reading)

Asset Management Measuring Points (PM & Fleet) Create Equip Create Measuring Point Close Asset Maintenance Management

(20)

Fleet Measuring Point (KM & Fuel Consumption

reading)

SAP - Processing of Measurement Points process

flow

1. Display equipment master for vehicle w/

Measuring point (IE03)

2. Display & Changes measuring point list (IK32)

i.e. 2000011

(21)

Asset Maintenance

Management

Asset Maintenance Management Conduct budget control

Perform intercompany spare parts sales Send fuel card information

Dismantle equipment

Asset Management Asset Maintenance Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Conduct Order Managed Modifications Install Capital Equipment Dismantle Capital Equipment

(22)

Conduct Order Managed Modifications

Asset Management Project Execution For Assets Order Managed Modifications Request for project modificati on Finance Approval for WBS Notificatio n approved Create order & release Confirmati on Close order & Notification (TECO) Finance settle to WBS

Conduct Order Managed Modifications

A modification to equipment & function

location is made to improve its

performance or to prolong its usable

life. This is a planned intervention, for

which a cost estimate and approval is

required. This process adds value back

(23)

Conduct Order Managed Modifications

SAP - Order Managed Modifications process flow

1. Create Project request (IW21)

2. Create CapEx order & release (IW31)

3. Order Confirmation (IW41)

4. Close order & notification (TECO) (IW41)

5. Display WBS (CJ03)

6. WBS Expenses /Budget, Plan & Actual cost report

(S_ALR_87013558)

(24)

Install Capital Equipment

Asset Management Project Execution For Assets Install Capital Equipment

Install

Capital Equipment

Maintenance departments are

commonly used to assist with the

installation of Capital Equipment.

This process describes the use of

the Maintenance Order to

procure the equipment and the

settle it to WBS elements and the

settlement of the labor to

expense cost elements.

Request for project installatio n Finance Approval for WBS Notificatio n approved Create order & release Confirmati on Close order & Notification (TECO) Finance settle to WBS

(25)

Install Capital Equipment

SAP – Install Capital Equipment process flow

(26)

Dismantle Equipment

Asset Management Project Execution For Assets Dismantle Equipment

Dismantle Equipment

Within Capital Projects, an expense

portion can exist in the dismantling

or demolition of the equipment.

This process make use of the

Maintenance Order to accomplish.

It also triggers the need for asset

disposition and changes to

functional location structures

within R/3.

Request for Dismantle Finance Approval for WBS Notificatio n approved Create order & release Confirmati on Close order & Notification (TECO) Finance settle to WBS

(27)

Dismantle Equipment

1. Dismantle Equipment

Process (IE02)

(28)

Preventive/

Predictive

Maintenance

Asset Maintenance Management

Dismantle equipment

Asset Management Asset Management Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Preventive/ Predictive Maintenance

(29)

Perform Preventive/Predictive Maintenance

29

Preventive

Maintenance

Maintenance Plan

Schedule the Plan

Create PM Orders

Adjust planned

dates if required

Release the Order

Execute Maintenance

Maint. Operation

Confirmation

Technically complete

the order

Record technical data

in notification

(30)

30 30

Strategy plan

Time-based

Performance-based

Maintenance plans

(31)

Preventive Maintenance Plan: Structure

Maintenance items

Preventive

maintenance plan

Maintenance

Schedule

Maintenance orders

Preventive

Maintenance

strategy

Maintenance

task list

Maintenance items

31

Maintenance

Package

(32)

(33)

Perform Preventive Predictive Maintenance

SAP - Preventive maintenance process flow

1. Maintenance Strategy Display (IP12)

2. General Maintenance Task List Display (IA07)

3. Maintenance Plan Display (IP03)

4. Maintenance Plan Scheduling

Display/Reschedule/Manual Call (IP10)

(34)

Corrective

Maintenance

Asset Maintenance Management

Dismantle equipment

Conduct emergency breakdown maintenance Perform low cost repairs

Perform Planned Repairs Refurbish spare parts

Asset Management Asset Management Management Project Execution For Assets Preventive/ Predictive Maintenance Corrective Maintenance Perform Emergency Repairs Perform Low Cost Repairs Perform Planned Repairs Refurbish Spare Parts

(35)

Conduct Emergency Breakdown Maintenance

Asset Management Corrective Maintenance Emergency Breakdown Maintenance Break down Notification & Release Work Order & Release Confirm

TECO

(36)

Conduct Emergency Breakdown Maintenance

1. Create PM Notification- ZU (IW21)

SAP - Emergency Breakdown process flow

2. Create Order & Release (IW31)

3. Order Confirmation (IW41)

4. TECO (IW32)

(37)

37

Perform Low Cost Repairs

• Within a limited range, a technician may confirm times, and only times, to

a standing order as long as there is no goods issue involved (no spare parts

consumed).

• If a goods issue is involved or the time limit is exceeded, the technician

has to trigger the release process for a notification and order.

• The work order is only open for a specified time period

• Notifications are created for low cost jobs and linked to the open work

order

Asset Management Corrective Maintenance Perform Low Cost Repairs

(38)

• Create Standing Work Order (ZP)

• Create Notifications (ZU)

• Assign Notifications to Standing Work Order

• Confirm Notifications

• Standing Order Low Effort Not. Assign Not. To Order Confirm Close Order

(39)

Perform Low Cost Repairs

Low Cost Repairs – Process flow

2. Create PM Notification (Low cost assign to order) (IW21)

1. Create Order & Release – Open order, ZP03(IW31)

3. Operation Confirmation (IW41)

5. TECO (After 6M or 1Y) (IW32)

(40)

Perform Planned Repairs Process Flow

Asset Management Corrective Maintenance Perform Planned Repairs Problem ID’d Notify Create WO Plan WO Schedule WO Execute WO Doc & Close

(41)

Perform Planned Repairs

SAP - Planned Repairs process flow

1. Create PM Notification- ZP - (IW21)

2. Create Order & Release (IW31)

3. Order Confirmation (IW41)

(42)

Refurbish Spare Parts

Bought stock and

put into spares

Special type of

maintenance

order

Broken Item

Asset Management Corrective Maintenance Refurbish Spare Parts

(43)

• High value materials or spare parts, such as motors, are often used in production systems. In the event of failure or damage to these types of parts, they may be replaced by a functioning spare, then refurbished in the

maintenance department or externally if deemed more cost effective to do so. Refurbishment is frequently

considered more cost effective and should be applied when this is the case. The cost to process the routine has to be weighed also, considering planner time, purchaser time, and storeroom attendant time. With this in mind, as a guideline, spare parts having an individual value of 500 Euros or more (roughly $750) should only be considered for refurbishment. Only in special cases should other parts be put into the refurbishment process.

• In typical corrective maintenance repair processes, some described above, work order are set for the consumption of materials or parts. In the refurbishment process, work orders are intended to repair the defective part. To accomplish this, the refurbishable material has to be classified by 3 different states, called valuation types. They are: New, Refurbished, and Defective. The valuation types have been set up in the system as:

•

Refurbish Spare Parts

Asset Management Corrective Maintenance Refurbish Spare Parts

(44)

Refurbish Spare Parts

SAP - Refurbishment of spare parts process flow

1. Create Order & Release – (IW81)

2. Order Confirmation (IW41)

3. TECO – Order close (IW32)

(45)

Material Masters

• The material master contains descriptions of the articles and parts that the plant, manufactures, and

stores. The material master is the central source for calling up material specific information within the

plant. Since all the material data is integrated in one master record, the problem of data redundancy is

minimized. This integration also enables the stored data to be used jointly by purchasing and other areas

such as Inventory Management, Material Request Planning (MRP), and Accounts Payable.

• Plant Maintenance uses the following Material Types.

 ZDIE

SCALE Services

 ZENS

PM Spares Non Standardized Local

 ZESS

PM Spares Standardized Global

 ZIMA

Maintenance Assemblies

 ZNFA

Fixed Assets

 ZNNM

Non-Stock Materials

 ZNVM

Non Valuated Material

(46)

Material Masters

SAP – Stock Item process flow

1. Materials List Display (MMBE)

2. P.R. List Display (MN53N)

(47)

Order - with Stock Item material

Released Planned Wos (ZP01, ZP03, etc)

Work Order

0010 Check pump

0020 Renew seals Material

Issue/ Pick Lists Problem ID’d Create Notificatio n & Release Create order (+ Materials) & released Received materials Confirm order TECO & Close Order

(48)

Material

SAP – Stock Item process flow

1. Create Notification & Release (IW21)

3. Goods Receive Process (MIGO)

4. Confirm order (IW41)

5. TECO and close order (IW32)

(49)

Order - with Non-Stock Item Material

Released Planned Wos (ZP01, ZP03, etc)

Work Order

0010 Check pump

0020 Renew seals Material

Issue/ Pick Lists Problem Create Notificati on & Release Create order (+ Materials) & released PR Created Automatically