Sap Plant Maintenance Pm Business Blueprint Bbp

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SAP R/3 IMPLEMENTATION

BUSINESS BLUEPRINT

Plant Maintenance

Prepared by

Checked by Reviewed By Signature Approved By Signature

Date

Mr. Krishna

Mr. Swain

Mr. Coumar

Mr. Kanada

Vishal Rathore Pinaki Roy

Mr. Manna

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Based on this As-Is coupled with inputs from the core team members during To-Be discussion, we arrived at the Business Processes, which are incorporated in the Business Blue Print. The aim of this document is to map the best business processes related to the Plant Maintenance module in SAP ECC 5.0. This document is to be studied by core team members & process owners from Vedanta Alumina Limited. The preparation of this document is an essential precursor to prototyping and testing. The development work will start once process owner’s approval for this Blue Print is obtained followed by a corporate presentation to the senior management team, Vedanta Alumina Limited.

This document will be used for configuring Plant Maintenance module in SAP implementation. Document is based on discussions/presentations between representatives of VAL & PWC. In other words it contains

1. SAP Organization Model in context of existing business scenario and future requirements/issues as envisaged by VAL. 2. Mapping of business processes/issues brought forward by PwC & VAL, with SAP functionality

3. Gaps & issues emerged during the discussion between VAL & PwC 4. Business Process Flows mapped in SAP as per the scope defined.

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5. Closure of Mapping Phase and start of Piloting Phase of implementation

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SCOPE OF BPBP DOCUMENT

The objective of this Blue Print presented to the Project Sponsor is to document the following:

a) Business Requirements of VAL that need to be translated into SAP.

This has been prepared by SAP consultants team members on the basis of As-Is document, factory visit & discussions between PwC SAP consultants and VAL core team members.

b) SAP Gaps as identified by PwC Team w.r.t. The present scope of implementation and Business Requirements of VAL.

c) Details of SAP New Business Process description supported by Process Flow diagram w.r.t. Different SAP process indicating the desired “To be Processes”.

In order to bring the clarity and better understanding, the document has been divided in five sections:

SECTION I : Scope of SAP Plant Maintenance module for the project SECTION II : Organization structure

SECTION III : Master Data Management, As-Is/ To-Be Business processes, and Gaps identified for business processes as per SAP. SECTION IV: Appendix-Process Flow Diagrams.

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Plant Maintenance in SAP - Objective

Ø To have Reliable Equipments with low MTTR and high MTBF

Ø To have Predictive and Condition –based plans that help to improve equipment availability.

Ø To eliminate repetitive breakdowns and thereby reduce wastage of valuable resources

Ø To have a Preventive Maintenance Plan in place that helps to maintain Equipment Health.

Ø To eliminate the need to pull out data from different systems for reporting purposes.

Ø To draw a long-term plan for Spares requirement and also help in Budgeting.

Ø These objectives will be obtained by

Ø By detailed analysis of downtimes and designing a Corrective Action Plan based on this analysis.

Ø By having up to date cost figures (Plant-wise/Location-wise/Equipment-wise) for better maintenance decision-making

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SECTION I

Scope of Plant Maintenance Module in VAL

PARTICULARS ALUMINA POWER

Master

1.1 General Master Records

1.1.1 Material Master X X

1.1.2 Material BOM X X

1.1.3 Work Center X X

1.1.4 Service Master X X MM

1.2 Plant Maintenance

1.2.1 Technical Objects (Structuring of Technical Systems) X X

1.2.2 Measuring Points & Measuring Documents X X

1.2.3 Warrantees X X 1.2.4 Permits X X 1.2.5 Task Lists X X 1.2.6 Maintenance Strategy X X 1.2.7 Maintenance Plans X X Business 2.1 Plant Maintenance

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PARTICULARS ALUMINA POWER

2.1.1.1 Notification X X

2.1.1.2 Order X X

2.1.1.3 Material Movements X X

2.1.1.4 Completion Confirmation X X

2.1.2.5 Confirmation of external services through service sheet X X

2.1.1.6 Settlement and Completion X X

2.1.1.7 Evaluations: Information System X X

2.1.2 Preventive / Shut Down Maintenance Processing

2.1.2.1 Maintenance Planning X X 2.1.2.2 Worklist X X 2.1.2.3 Notification X X 2.1.2.4 Deadline Monitoring X X 2.1.2.5 Order X X 2.1.2.6 Material Movements X X 2.1.2.7 Completion Confirmation X X

2.1.2.9 Evaluations: Information System X X

2.1.3 Refurbishment Processing in Plant Maintenance

2.1.3.1 Order X X

2.1.3.2 Material Movements X X

2.1.3.3 Completion Confirmation X X

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PARTICULARS ALUMINA POWER 2.1.4 Development/Improvement/Re-Design Orders X X 2.1.5 Calibration Orders X X PM/QM 2.2 Inventory Management 2.2.1 Goods Movements 2.2.1.1 Reservation X X 2.2.1.2 Purchase requisition MM 2.2.1.3 Goods Receipt MM

2.2.1.4 Stock Transfers / Trans. Postings MM

2.2.1.5 Goods Issue X X Cross-Application Components 3.1 Classification System 3.1.1 Characteristics X X 3.1.2 Classes X X 3.1.3 Classification X X

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Section II

Organization Structure

Plants

The plant is an operating area or branch within a company. The plant is assigned to a single company code. A plant has its own material master data. You can maintain data at plant level for the following views on a material master record in particular: MRP, Purchasing, Storage, Work scheduling, Production resources/tools, Forecasting, Quality management, Sales, Costing.

As per discussion with Finance & Materials, there will be only four Company Codes and four plants will be created which may be as follows: VAL Alumina 1000

VAL Power 2000

VAL Smelter 3000

VAL JV 4000

Out of this, the VAL Alumina Plant (1000), VAL Power Plant (2000) will have complete PM Implementation while the VAL smelter Plant (3000) and JV (4000) will only have PM basic organization structure.

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Maintenance Plant

In Plant Maintenance, a distinction is made between the organizational units "planning plant" and "maintenance plant".

• Maintenance plant

In a maintenance plant, you can manage technical objects and main work centers.

• Planning plant

In the planning plant, maintenance task lists are defined for the respective maintenance plants, material planning is carried out on the basis of bills of material in task lists and orders, maintenance plans are managed and scheduled, maintenance notifications are created and maintenance orders can be handled.

With discussion for the Organization Structure for Maintenance Planning, it has been decided to follow the based on the Material Management Plant Code. Since maintenance Planning is independent of all four plants, hence there will be four maintenance planning plants in Plant Maintenance Organization Structure. They are as follows:

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MAINTENANCE

PLANT DESCRIPTION

1000 VAL Alumina Maintenance Plant

2000 VAL Power Maintenance Plant

3000 VAL Smelter Maintenance Plant

4000 VAL JV Maintenance Plant

MAINTENANCE

PLANNING PLANT DESCRIPTION

1000 VAL Alumina Maintenance Planning Plant

2000 VAL Power Maintenance Planning Plant

3000 VAL Smelter Maintenance Planning Plant

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Locations

A location is the physical location to identify where the equipment lies. This data helps the Plant Maintenance person to identify where the equipment is located. Here location, plant section, room number etc. can be mentioned.

Proposed locations for Vedanta Alumina Limited are as follows:

For Alumina Plant (1000)

Location DESCRIPTION

RED Red Area

WHT White Area

UTL Utilities

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For Power Plant (2000)

TGU Power Generation

BLR Steam Generation

BOP Balance of Plant

For Mining Plant (4000)

MIN Mining

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Planner Group

Planner groups or maintenance planning groups must be defined separately for each planning plant.

Depending on the size and structure of your company, a maintenance-planning group may be an individual department (for central work preparation), a group of skilled craftsmen or a workshop.

Every piece of equipment and functional location can be allocated to a maintenance-planning group. Maintenance planning groups can also be used for evaluation purposes.

In Vedanta Alumina Limited we have identified FOUR planner groups for each plants

For Alumina Plant (1000)

Planner Group DESCRIPTION

101 Mechanical Planner Group

102 Electrical Planner Group

103 Instrumentation Planner Group

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For Power Plant (2000)

202 Electrical Planner Group

203 Instrumentation Planner Group

204 Civil planner Group

For Mining Plant (4000)

402 Electrical & Instrumentation _{Planner Group}

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Functional Location category

Functional Location Category to be used – “M” – Technical System Standard

Functional Location Structure Indicator

We shall be using the following Structure Indicator for Functional Location Labelling:

STRUCTURE

INDICATOR DESCRIPTION STRUCTURE

VAL01 Indicator for Alumina Plant NNNN--AAA-AAA-XXX-XXXX-XXXXX

VAL02 Indicator for Power Plant NNNN- AAA-XXX-XXX-XXX-XXX

VAL03 Indicator for Mining Plant NNNN- AAA-XXX-XXX-XXX-XXX

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Example:

1000-RED-DIG-TR0-DIGV-DIG01 1000 – Vedanta Alumina Plant DIG – Digester Area

TR0 – Train 0 Area DIGV – Digestion Vessel DIG01 – Digester 01

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Equipment Categories and Equipment Codification

Equipment Categogy for all the equipment will be used as ‘M’

It has been decided that the Equipment Code will be Externally generated for easy identification and the logic for that code will be

XX XXX NNNN

Main Group Sub-Group Number

Spare Parts / Assemblies / Components codification

All the spare parts, assemblies, components, consumables for maintenance will be defined as material in SAP for taking them in inventory and the material code will be externally generated. Logic for the material code is

XX XX XXX XXXXX

Major Group Sub Group Sub- Sub Group Material No

• The codification is external.

• 12 digit codification, split as mentioned above.

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1. For bearings, the codification will be strictly with the engineering department. 2. Flag in the system for insurance spares.

3. Flag for the regular inventory items.

4. Flag for the value capture of all the materials.

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Technical Object Types

This implies a division of a technical object for precise description.

All equipments at VAL would be categorized into various Technical Object Types. An indicative list of technical objects is given below.

Alumina Plant

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Power Plant

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Catalog Profile

Combination of code groups, which determine from a functional viewpoint, which code groups can be used for a particular technical object. The following catalogs would be used for VAL. Common catalog profile will be used for different technical object types.

n Coding - D n Object parts – B

n Problem/Event Codes – 4 n Cause Codes – 5

n Activity Codes – A

We shall be using common catalog profile for all equipments. Details of the catalogs would be maintained as follows: Ø Coding: Coding of breakdowns as Serious/Semi-serious/Normal

Ø Object Parts: All critical Mechanical and Electrical parts would be configured for each of the technical object types defined. Ø Problem/Event Codes: All problems that normally occur or might occur would be listed for each type of Technical Object. Ø Cause Codes: All probable causes of the events/problems listed above would be configured for each technical object type. Ø Activity Codes: The normal activities (generic) carried out for attending to the problems would be configured here.

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Example:

Technical Object Type : Pump

Object Parts Problems Causes Activities

Impeller Impeller Broken Improper Cleaning Cleaned

Bearing Impeller Jammed Lubrication Failure Machined

Casing Bearing Damaged Life Expiry Rewinding Done

Shaft Abnormal Sound Impeller nut Loose Reset

Pressure Low Misalignment Replaced

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Notification Types

Various Notification Types would be configured in the System to take care of the various types of job requirements.

NOTIFICATION TYPE DESCRIPTION

M1 Maintenance Request (Predictive w/o production loss)

M2 Breakdown Report (Breakdown Maintenance with production loss)

M3 Activity Report (Preventive Maintenance)

M5 Improvement (Modification/Development/Re-Design) Notification

M6 Safety Notification

M7 Shutdown Notification

M8 Calibration Notification

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Maintenance Order Types

Seven different types of Maintenance orders will be defined for the various types of maintenance/repair activities to be carried out.

MAINTENANCE ORDER TYPE DESCRIPTION

PM01 Maintenance order w/o production loss

PM02 Breakdown order with production loss

PM03 Preventive maintenance order

PM04 Re-furbishment Order

PM05 Improvement (Modification/Development/Re-Design) order

PM06 Safety Order

PM07 Shutdown Order

PM08 Calibration Order

PM09 Workshop Orders

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Assignment of Notification Types to Order Types

Notification type Order type

M1 PM01 M2 PM02 M3 PM03 M5 PM05 M6 PM06 M7 PM07 M8 PM08 M9 PM09

There will be no notification for refurbishment orders & Annual Maintenance Orders.

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SECTION III

To-Be Processes

Plant Maintenance Processes

The Business Blue Print is divided into various sections as defined by the different processes as discussed during to-be and Expectation from SAP. These processes are:

Routine/Predictive Maintenance Breakdown Maintenance

Preventive Maintenance (based on duration and measuring point) Refurbishment Spares

Improvement / Development / Modification / Re-design Maintenance Shutdown Maintenance (Planned maintenance)

General Maintenance (to be done through maintenance request) Annual Maintenance Orders

Maintenance Budgeting (Through FI/CO Module)

Condition Monitoring (Through measuring points/counters) Spare Part Planning

Report Analysis

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No. Process Name Mode Process Description/remarks (Y/N) Gap Remarks

1.0 Masters

1.1 Spare Parts, Components, Assemblies

Fully system supported

All Spare Parts, Consumables used in building of machine or repair will get a unique material code. This code will be unique for the whole organisation and will not change at Plant level. Basic data of the materials will be maintained at client level while the other data will be maintained at purchase organization and plant level.

The material master for spare parts will have several views like Basic Data, Purchasing View, MRP, Accounting view etc.

The Spare Parts, which are accepted after inspection will be subjected to Quality Inspection. For such material Quality Management View will be activated and necessary master date will be created for the automatic inspection lot creation and results recording and usage decision for the Spare parts.

For VED analysis (V-Vital, E-Essential, D-Desirable) one field will be used in the material master of the spares so that this analysis can be done. N Will be done with the co-ordination of MM

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1.2 Valuation type of _{Spare Parts} Fully system supported

The spare part in SAP is maintained with the valuation category. In the valuation category, the valuation type is maintained. These valuation types can be damage, repair etc. Each of the valuation type has certain value attached to it.

During the maintenance activities, spare parts are replaced with new or repaired one. The defective spare parts are repaired also. In SAP, the maintenance and cost of repair of such defective spare parts is maintained using Refurbishment Order. Repaired part can be stored at different storage location.

The activity is directly linked to MM as well. Hence the valuation class and type will be in accordance and consultation with MM.

N Will be done with the co-ordination of MM

1.3 Catalog Fully system supported

Catalogs are used to manage, uniformly define, and standardize information (for example, cause analysis for the failure of the machine) on a client-wide basis. The catalogs help in recording the information with ease and sorting out the activities as well.

In the catalogs, each unit of information is assigned a unique alphanumeric code and an explanatory text.

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The different catalog types are Object Parts, Cause, Damage, Task, Activities, etc. The task and Activities are similar with different presentation structures. In Task Screen, for each task, Planned Start date, Planned Finish date, Completed By and Completion Date can be mentioned. In Activities Screen, Start Date and End Date can be mentioned.

1.4 Code Group Fully system supported

Code groups are used to combine and structure codes within a catalog type. Code groups are used at client level to group codes that have the same contents or relate to one another, within a catalog type. Assigned codes to a group are called as Code Group.

N 1.5 Functional Location Create / Change/Display Functional Location Master Data Fully system supported

Functional location is an organizational unit within Logistics, which structures the maintenance objects of a company according to functional, process-related or spatial criteria. A functional location represents the place at which a maintenance task is to be performed.

A functional location represents an area at which an object can be

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installed. The objects that can be installed at functional locations are called pieces of equipment

Records can be kept of the maintenance tasks that are performed; technical data can be collected and evaluated over long periods of time and the costs of maintenance tasks can be monitored for the individual areas. Analysis can be carried out on the influence of usage conditions on the damage susceptibility of the pieces of equipment installed. 1.6 Equipment Master Create/Change/Displa y Equipment master Data Fully system supported

The use of equipment master records in the Plant Maintenance (PM) application component enables to define individual machine, motor as a piece of equipment. Equipment for which any maintenance activities are carried out, are maintained in the Equipment Master. The cost of maintenance of equipment based on type of maintenance can be monitored.

If the equipment is very big, then equipment and sub-equipment can be created in SAP.

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1.6.1 Start up & _{Acquisition Date} Fully system supported

The Start up date field indicates the installation & commissioning date. This indicates the date on which the equipment is operational.

The Acquisition date indicates when the asset is purchased.

The use of this date is for information as well as for deciding the ageing of the equipment so that the maintenance planning can be updated e.g. during the initial installation period the preventive maintenance requirement is lower but after years of usage, the requirement of preventive maintenance planning frequency increases.

N

1.6.2 ABC Indicator Fully system supported

The ABC Indicator in an Equipment signifies the importance of that equipment in the manufacturing scenario. This helps in prioritising the maintenance planner to execute the maintenance activities in the plant.

There will be four types for maintenance and one for calibration for the ABC Indicator as the outcome of the discussion:

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A: Very high Production Loss B: Major Production Loss C: Minor Production Loss

D: No production loss (Spare assembly) Q: Quality Loss (for Calibration Instruments)

1.6.3 Warranty Fully system supported

Warranties define the scope of the services that a company performs at a technical object in the event of damage or problems. It is a commitment of the manufacturer, vendor, or retailer to guarantee services to a customer either free-of-charge or only charged in part, over a certain period of time.

The warranty period of the equipment can be mentioned in the equipment master. This gets pop up when a user wants to create maintenance order for the equipment during the warranty period.

N

1.6.7 Permits Fully system

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Permits are used to ensure that special approval must be obtained before orders are executed.

Permits can be assigned to the following objects:

• Technical objects – functional locations and equipment

• Orders

Permits can cover the following areas:

• The way the order is executed or the safety aspects

involved

Safety precautions for the employees and surroundings: Providing ear protection for employees or acidproof equipment, safeguarding the work area, installing a flame-proof zone, work clearance certificate

• How the execution of an order is organized

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1.7 Budget System _supported

Budget for maintenance can be done at the maintenance cost center level. Apart from budget, we can also give the planned expenses for maintenance.

Cost center and budget will be done in CO module.

N Through FI/CO Module 1.8 Classification Creation/change of Class and Characteristics Fully system supported

The classification system allows you to use characteristics to describe all types of objects, and to group similar objects in classes – to classify objects, in other words, so that you can find them more easily later.

You then use the classes to help you to find objects more easily, using the characteristics defined in them as search criteria. This ensures that you can find objects with similar or identical characteristics as quickly as possible.

Characteristic is a property that describes and differentiates objects.

Example: length, color, weight, etc.

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Class is an assembly of characteristics that can be attributed to a product (or to several similar products). It can also be defined as a grouping of similar products according to common characteristics Example – Pump class, Boiler class etc.

1.9 Maintenance Strategy Creation/Change of Maintenance strategy Fully system supported

A rule for the sequence of planned maintenance and predefined tasks.

A maintenance strategy contains the maintenance packages that define the cycle in which the tasks must be performed, for example, every two months, every 5,000 km, every 500 operating hours. Maintenance strategies are obligatory in strategy plans.

N 1.10 Work Center Creation/Change of Work centers Fully system supported

Work center describes the logical station where work is being carried out.

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1.11 Maintenance Task List Creation/Change of Task-lists (For Preventive Maintenance, Shut down Activities, and Calibration)

Equipment Task List is the description of the procedure for maintaining a maintenance object called Equipment. Maintenance task lists is the generic term used for all task lists specifically to Equipment task list. A maintenance task list contains operation. The maintenance task list uses a strategy for planning of Equipment Maintenance for the defined period say weekly, monthly, quarterly etc. Operation can be processed internally or externally. The activities defined for an external operation are requested using orders.

There are two types of Equipment Task List: Equipment Task List and General Task List. Equipment task List can be attached only to one Equipment Task List. But General Maintenance Task List can be attached to several Equipments. The General Equipment task List is used for the Preventive Maintenance where the similar equipments undergo Preventive Maintenance Scheduling.

N 1.12 Strategy Plan Creation/Change of Maintenance Plans Fully system supported

Strategy Plan defines the description of maintenance and tasks to be performed on maintenance objects. The dates and scope of the tasks are also defined here.

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(For Preventive Maintenance, Shut down Activities, Calibration

A maintenance plan is structured based on a maintenance strategy. A maintenance plan contains one or more maintenance items, in which the maintenance objects to be maintained and the corresponding task list has been defined. The maintenance tasks to be performed on a due date are determined by the maintenance task list assigned to the maintenance item. The necessary maintenance orders are automatically generated for a due maintenance date.

1.13 Scheduling for the Equipment Fully system supported

Based on the maintenance plan, we can schedule the Preventive/Shut down/Calibration Plan for the whole of the scheduling period or we can use deadline monitoring to carry out the scheduling of the Preventive Maintenance Orders for fixed period of say one month etc.

N

1.14

Equipment / Material BOM (Bill of Material) Creation/ Change of BOM Fully system supported

Any equipment is made of some assemblies and the assemblies are further made of spare parts and small components down the

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The equipment BOM gives ready list available to record the

critical spare part list for any equipment. The same list can be

referred to create preventive maintenance planning.

In the equipment BOM, create the spare part list, quantity and stock type (non-stock or stock item). This master helps in identifying for which material Purchase Requisition will be made or Reservation is created.

For assemblies also we need to create BOM (Material BOM).

1.15 Measuring Points and Counters Creation/ Change of Measuring Points Fully system supported

A physical or logical place at which a condition is described. Example can be Temperature inside a reactor, Speed of revolution of a wind wheel, the status is described using measurement readings, the operating duration of Diesel Generator etc.

Measuring points are stored in the SAP System as master data for the Equipment. It can work as a counter to record the duration, based on manufacturer guidelines, the Preventive Maintenance Orders can be generated for the same.

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Counter are defined as Measuring Point in SAP and Counter readings are taken at counters at particular intervals and in particular measurement units. For example, counter readings for kilometers driven, operating hours or electricity used.

2.0 Notification Fully system supported

A key that determines the origin, content, and other features of maintenance activities. The Maintenance notification includes malfunction, activity reports and maintenance requests. It gives the equipment location data, malfunction start and end date/time, duration of total breakdown, priority etc.

Maintenance notifications document maintenance tasks

completely, and make them available for analysis in the long term. You can use them for preliminary planning and execution of tasks.

N

3.0 Maintenance Order Fully system supported

Order is a task to perform within a company. The order specifies the type of task to perform, how and when it will be performed. It also defines the rules for the settlement of the costs.

Maintenance order to be used whenever any cost is involved for

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maintenance activity, i.e., external services required or components required for maintenance. Orders will be used in Plant Maintenance Module for classifying different type of activities for an equipment, functional location etc.

For the new purchased assets, Internal Order can be used for cost involved in purchasing, erecting and commissioning activities. These orders will be created in CO module.

4.0 External Services Fully system supported

External Services are the external support required from the expert for the maintenance of equipments. This process can be required for Preventive, Breakdown or any other type of maintenance. Hence this becomes a common process required for any maintenance activities.

The different steps of confirming an external service are given below.

N

4.1 Creation of operation using PM03 control key

In general, Plant Maintenance Internal control Key (PM01) is used. Wherever the external services are required, in the relevant

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operation of that order, the PM03 (Plant Maintenance External Services) control key is used. Using this key, the system requires the Service No. / Description, Quantity and price of the service. Based on the MM requirement for Purchase Requisition, certain fields are required to enter.

On saving the order, the system creates the Purchase Requisition number for the external services. This PR number is used to create the Service Purchase Order by MM.

4.2 Confirming the _{External Services} Fully system supported

For confirmation of external services, Service Entry Sheet is used. The service entry sheet is created with reference to the Service PO.

In the service entry sheet, the number or percentage of services is confirmed. Accordingly the data is updated in Controlling and Financial Accounting for releasing the payment for the external services.

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5.0 Predictive Maintenance/ Routine Maintenance/Gene ral Maintenance Fully system supported

There are many instances when based on the noise factor, heat dissipation etc. the prediction of machine failure can be made. In such cases, maintenance activities are carried using Predictive Maintenance. The decisive factor in this case is that there is no malfunction.

Here Predictive Maintenance Notification is created to record the damage cause, activities undertaken.

N 5.1 Notification by the user / maintenance in-charge of the machine (M1) Fully system supported

User / maintenance in-charge creates a Predictive Maintenance Notification (Maintenance Request) based on the abnormal behaviour indicated in the machine during the operation in the machine. Notification type M1 is to be used. In this the status of the machine before and after malfunction, date and time of malfunction and priority etc. are defined.

The location and other necessary data get copied into the notification from the equipment master.

N

5.2 Create maintenance order from

Notification

After receipt of the notification, the maintenance department

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screen of notification in change mode. Then describes the operations, requirement of spare parts for the maintenance activities in the order and Release for and issue of spares and confirming the activities.

If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.

5.3 Order Execution Fully system

supported

During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.

N

5.4 Order Completion _Confirmation Fully system

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confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial

confirmation, order must not yet have been completed fully. You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered.

You enter time completion confirmations for operations and sub-operations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.

5.5 View Costs Fully system

supported

The Planned vs. actual costs can be viewed after all issues and

service entry sheets are completed N

5.6 Change / Complete _Notification Fully system

supported

Notification will be closed after noting down all catalog & details of

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5.7 Technically and _{Business Completion} Fully system

supported

After confirmation for the maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.

When all the costs are settled and no further activities are pending against that order, business completion for the order is done.

N

6.0 Breakdown _Maintenance Fully system supported

The Breakdown maintenance refers to the sudden failure of the machine to produce the desired results / output.

An employee from production would use a malfunction report to report that:

• A production system is not functioning properly.

• Performance has reduced for a production system, or that

the system is not functioning at all.

• A production system is producing goods of poor quality.

This is carried using a formal intimation by user department for the maintenance of the equipment. The record of total repair time is used to calculate Mean Time To Repair.

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6.1

Notification by the user of the machine (Malfunction Report M2)

Like the Breakdown slip, here in SAP the user creates a breakdown notification to intimate the Maintenance Department for the breakdown in the machine. In this the user defines the status of the machine, date and time of breakdown and priority of the breakdown.

N

Notification

After receipt of the notification, the maintenance department creates the Maintenance Order (Order Type - PM02) using the screen of notification in change mode. Then describes the operations, requirement of spare parts for the maintenance activities in the order and Release for and issue of spares and confirming the activities.

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supported

N

supported

After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial

You enter time completion confirmations for operations and

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operations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.

supported

maintenance required to be recorded. N

supported

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7.0 Preventive _Maintenance Fully system supported

Preventive maintenance is the scheduled / planned maintenance based on the manufacturer recommendation or own experience. Here a frequency called Strategy for Maintenance is maintained based on Duration or the operating hours.

The activities unlike other maintenance are much clear in advance and are documented in the maintenance Task list. The spare parts as well can be planned and stocked for the periodic maintenance activities. N 7.1 Preventive Maintenance order generation from schedule. Fully system supported

In Preventive Maintenance, certain master data needs to be maintained. The task list, strategy plan, measurement counter (optional) etc. are maintained for equipment. Measurement Counter uses a class characteristics say operating duration. The counter is created for the equipment. For recording the status / data of the counter, measurement document is created.

The equipment task list contains the list of operation and sub-operations. The spare and consumables required for the completion of the maintenance operations can also be maintained

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in the task list. Based on the release of maintenance order, the reservation for the stock-able spares and consumables are created in the system. For non-stock spares, the PR is created from the maintenance order.

The equipment plans are then scheduled (periodically) using deadline monitoring for a target period of say one month. The scheduling creates Preventive Maintenance Orders (Order type – PM03) automatically for the period.

7.2 Notification for recording activities Activity Report (M3) Fully system supported

On the due date, the required spares can be issued from the store. Based on the order created, a notification is also generated by the system. The purpose to create a notification is to record the activities done during the Preventive Maintenance. Also it can be the ready reference for the activities left for future Maintenance. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.

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supported

N

7.4 Order Completion _confirmation Fully system

supported

You enter time completion confirmations for operations and

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operations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.

supported

7.7 Technically & _{Business Completion} Fully system

supported

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8.0 Refurbishment _Order Fully system supported

Refurbishment order is the special order, which are used for the refurbishment of repairable spares. In the refurbishment order, contract a work centre to restore faulty repairable spares to full working order at a certain date.

The repairable spares scheduled in the order are brought from a uniform initial condition to a uniform end condition. To distinguish the condition of damage to repair for spares different valuation types are used.

N

8.1 Notification for Refurbishment (M4) Fully system

supported

Maintenance person will create a notification to intimate the

workshop Department for the refurbishment in the component N

8.2

Create Refurbishment Order for the damage spare

Order Type (PM04)

Create the Refurbishment order with order type PM04. The order is created for the damaged Spare Part Material. The valuation type of spares is maintained in the Accounting 1 view in the material master.

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Create appropriate operations with internal maintenance, consumables required for the Repair of the spare part. The valuation type present and future (after repair) is mentioned in the order. Release the order and save it.

supported

During refurbishment of spare (outside SAP), consumables required will be issued against the reservation created in the order. Internal maintenance will be carried inside the plant. After that for external repair, MM will create subcontracting order for the spare. The receipt of the subcontracting order will result into the valuation type change from damage to repair and cost of repair will be loaded into the spare.

For internal maintenance, the spare will be repaired using internal spares and consumables. The cost of such repair will be settled to the maintenance cost centre.

N

supported

After completion of maintenance activities for the spare, all the

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valuation type, the spare valuation is modified from the damage to repair and good receipt is made for the spare.

supported

service entry sheets are completed. N

supported

N

9.0 Safety Order Fully system supported

A Safety activity describes a notification meant for carrying out

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9.1 Notification by the user / maintenance in-charge of the equipment (M6) Fully system supported

User / maintenance in-charge creates a Notification for activities required for safety purpose for the equipment.

N

Notification

After receipt / creation of the notification, the maintenance planner creates the Maintenance Order (Order Type- PM06) using the screen of notification in change mode.

The other way is to create order directly, describing the operations, requirement of material for the development activities in the order and Release the order.

N

supported

During maintenance of the machine (outside SAP), spares required

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reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.

supported

You enter time completion confirmations for operations and sub-operations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable

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issued material can be returned to stores from the order.

supported

After confirmation for the development maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.

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10.0 Improvement / Modification / Re-design / Development/CAP EX Fully system supported

Improvements, Developments, Modifications or design changes are necessary part of maintenance to upkeep the equipment for higher productivity period, lower breakdown repair time etc.

These design change / modifications costs will be separated from other costs of maintenance using a separate order type.

N 10.1 Notification by the user / maintenance in-charge of the equipment (M5) Fully system supported

User / maintenance in-charge creates a Notification for required design change / modification activities required for the equipment mentioning the purpose and results expected.

N

10.2 Create maintenance order from Notification

After receipt / creation of the notification, the maintenance planner creates the Maintenance Order (Order Type – PM05) using the screen of notification in change mode.

The other way is to create order directly, describing the

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operations, requirement of material for the design change / modification activities in the order and Release the order.

10.3 Order Execution Fully system supported

N

10.4 Order Completion _Confirmation Fully system supported

confirmation, order must not yet have been completed fully.

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You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered.

10.5 View Costs Fully system supported

10.6 Change / Complete _Notification Fully system supported

10.7 Technically and _{Business Completion} Fully system supported

After confirmation for the development maintenance order, the order needs to be technically completed and settled to the appropriate cost object based on settlement profile. The cost of

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appropriate cost object based on settlement profile. The cost of these types of orders can be settled to the fixed asset.

11.0 Shut Down _Maintenance Fully system supported

During plant shut down, maintenance department get good opportunity to do some maintenance work to upkeep the equipment for higher productivity period, lower breakdown repair time etc. Shutdown activities can be planned and scheduled in advance.

These shut down maintenance cost will be separated from other costs of maintenance using a separate order type.

Shut Down Activities for the equipment are planned therefore it can be taken similar to preventive maintenance.

N

11.1 Create maintenance _order Fully system supported

As per the schedule, system will generate shutdown orders (PM07)

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The other way is to create order directly, describing the operations, requirement of material for the design change / modification activities in the order and Release the order.

11.2 Shut Down _{Notification (M7)} Fully system supported

System will creates a Notification for shutdown activities required for the equipment mentioning the purpose and results expected. The location and other necessary data get copied into the notification from the equipment master.

N

During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by

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the MM. Upon receiving the material, it will be issued against the maintenance order.

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11.5 View Costs Fully system supported

11.6 Change / Complete _Notification Fully system supported

11.7 Technically and _{Business Completion} Fully system supported

After confirmation for the development maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.

N

12.0 Workshop Orders Fully system supported

The Workshop orders will be used for repair of spares/parts in the Central Workshop.

The expenditure of such maintenance is recorded through Workshop Notification only.

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12.1

Notification by the user / maintenance in-charge for the functional location (M9)

User / maintenance in-charge creates a Notification for required general maintenance activities required for the functional location mentioning the purpose.

The location and other necessary data get copied into the notification from the functional location master.

N

12.2 Create maintenance order from Notification (PM09)

After receipt / creation of the notification, the maintenance planner creates the Maintenance Order using the screen of notification in change mode.

The other way is to create order directly, describing the operations, requirement of material for the general maintenance activities in the order and Release the order.

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N

confirmation, order must not yet have been completed fully. You use the remaining functions for the completion of an order,

Sap Plant Maintenance Pm Business Blueprint Bbp

SAP R/3 IMPLEMENTATION

BUSINESS BLUEPRINT

Plant Maintenance

Prepared by

Checked by Reviewed By Signature Approved By Signature

Date

Mr. Krishna

Mr. Swain

Mr. Coumar

Mr. Kanada

Vishal Rathore Pinaki Roy

Mr. Manna

CONTENTS

SECTION I

Scope of Plant Maintenance Module in VAL

Section II

Organization Structure

Plants

Locations

Planner Group

Functional Location category

Functional Location Structure Indicator

Equipment Categories and Equipment Codification

Spare Parts / Assemblies / Components codification

Technical Object Types

Catalog Profile

Example:

Notification Types

Maintenance Order Types

Assignment of Notification Types to Order Types

To-Be Processes