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(1)

Plant Maintenance in SAP

A functional perspective

By – Gopinath

(2)

SAP R/3 - Overview

Overview: R/3 Overview and Integration

R/3 R/3 Client / Server Client / Server ABAP ABAP CO CO Controlling Controlling AM AM Asset Mgmt Asset Mgmt PS PS Project Project System System WF WF Workflow Workflow IS IS I ndustry I ndustry Solutions Solutions HR HR Human Human Resources Resources SD SD Sales & Sales & Di stribution Di stribution PP PP Production Production Pl anni ng Planning QM QM Quality Quality Mgmt Mgmt FI FI Financial Financial Accounti ng Accounti ng PM PM Plant Pl ant Main-tenance tenance MM MM Materials Materials Mgmt Mgmt System-Wide Concepts TeamSAP Academy R/3 Overview & Integration R/3 Applications

Support & Services Getting Started

(3)

Plant Maintenance - Overview

 SAP AG R

SAP R/3 Modules

Human Resources

Logistics

Accounting

Cross Application

Functions

R/3

R/3

Client / Server

Client / Server

ABAP

ABAP

FI FI Financial Financial Accounting Accounting CO CO Controlling Controlling TR TR Treasury Treasury PS PS Project Project System System WF WF Workflow Workflow IS IS Industry Industry Solutions Solutions MM MM Material Material Manag Manag.. HR HR Human Human Resources. Resources. SD SD Sales & Sales & Distrib Distrib.. PP PP Production Production Planning Planning QM QM Quality Quality Manag Manag.. PM PM Plant Plant Maint Maint..

(4)

Plant Maintenance - Overview

R SD MM PP QA PM HR FI CO AM PS WF IS

R/3

What Is Integration?



Common organizational structures throughout

the system



Seamless processing of common data between

applications



Comprehensive support and reference tools



Common reporting features and functionality



Object and application linking and overall system

communication

(5)

Plant Maintenance - Overview

 SAP AG 1999



Plant Maintenance is an integral part

of the company and has numerous

links 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)

Plant Maintenance - Overview

Functional locations

Equipment

Assemblies

Bills of material

Networks of technical objects

Maintenance notifications

Maintenance orders

PMIS Plant Maintenance Information System

EQM Technical Data

Task lists

Maintenance plans

PRM Preventive Maintenance

WOC Maintenance Processing

CRP Work Centers and Capacity

(7)

Plant Maintenance - Overview

 SAP AG 1999

Concept of Plant Maintenance

Bills of material Task lists Characteristics Classes Equipment / functional locations Cost records Cost center Maintenance work centers Maintenance notification Material reservation Material issues Maintenance order Capacity load Time confirmation Purchase requisition Maintenance strategies Maintenance plans Master data Planning Order processing Goods receipt / invoice receipt Purchase orders / release order

(8)

Plant Maintenance - Overview

Organizational Structures in Plant Maintenance

General Organizational Units in Logistics

Location-Based Organizational Units

Planning-Based Organizational Units Maintenance plant

For example, site, building, coordinate For example, production area, plant engineer Client

Maintenance planning plant

Maintenance work centers

For example, foreman, work scheduling

For example, mechanics Maintenance planner groups Plant section Location Plant Company code

(9)

Plant Maintenance - Overview

 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

(10)

Plant Maintenance - Overview

Maintenance Work Centers

Maintenance work centers

For example:

Welding

Metalworking

(11)

Plant Maintenance - Overview

 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

Links

Links



Activity types

 

Staffing assignment

 

Staffing assignment

 

Activity types

 

Activity types

 

Work center

 

Person

 

Qualification



Staffing assignment

 

Cost center

(12)

Plant Maintenance - Overview

Work Center: Main Functions

Work Center

Work Center

Costing data Costing data Default values for task lists

and orders

Default values for task lists

and orders Scheduling data and available capacity Scheduling data and available capacity

10

11

Costing Costing 2,724.00 1,200.00 124.00 4,048.00 2,724.00 1,200.00 124.00 4,048.00

Task list / order

Task list / order schedulingLead time

Capacity planning

Lead time scheduling Capacity planning

(13)

Plant Maintenance - Overview

 SAP AG 1999

Technical

Functional

Spatial

Functional location = multi-level, hierarchical structure,

organized according to ...

Criteria

(14)

Plant Maintenance - Overview

Criteria for Functional Locations



Execution of maintenance tasks



Recording of maintenance tasks



Data collection over long periods

of time



Cost monitoring by area



What effect do the usage

conditions have on the

likelihood of damage to the

installed aggregates?

(15)

Plant Maintenance - Overview

 SAP AG 1999

Automatic Assignment Upon Creation

C1-B Biological cleaning C1 C1 Clarification Clarification plant plant C1-M Mechanical cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station

Existing

functional

locations

New

functional

locations

C1-M01-2 Ventilator C1-M01-2

(16)

Plant Maintenance - Overview

Example of Functional Location Structure

C1-B Biological cleaning C1 C1 Clarification Clarification plant plant C1-M01-1 Reservoir C1-M01-2 Ventilator C1-M01-3 Sand dredger C1-M02-1 Reservoir C1-M02-2 Ventilator C1-M02-3 Fat dredger C1-B01-1 Pump 1 C1-B01-2 Pump 2 C1-B02-1 Ventilator C1-B02-2 Filter cell C1-M Mechanical cleaning C1-M01 Sand trap C1-B02-1A Valve 1 C1-B02-1B Valve 2 C1-B02-2A Inlet C1-B02-2B Filtrate level C1-B02-2C Outlet C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station 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)

Plant Maintenance - Overview

 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

(18)

Plant Maintenance - Overview

Equipment Master Record

Equipment master record

Equipment master record

Internal note

Internal note

Documents /

Documents /

technical drawings

technical drawings

Multilingual texts

Multilingual texts

Equipment usage

Equipment usage

Location A Location B

Classification

Classification

XList X X X X X X

Address / partner

Address / partner

Permits

Permits

Measuring points /

Measuring points /

counters

counters

0 4 7 10 1 2 3

General

General

Location

Location

Organization

Organization

Structure

Structure

(19)

Plant Maintenance - Overview

 SAP AG 1999

Bills of Material in Company

Engineering/design

bill of material

Costing

bill of material

Maintenance

bill of material

Production

bill of material

(20)

Plant Maintenance - Overview

Breakdown Maintenance: Business Scenario



For breakdown maintenance, the

data required for the other business

processes needs to entered quickly

and easily so that the subsequent

steps can be executed.

(21)

Plant Maintenance - Overview

 SAP AG 1999

Notification

Notification

Planning

Planning

Scheduling

Scheduling

Execution

Execution

Completion

Completion

History

Material usage, orders, notifications, PMIS, usage list

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

4

4

5

5

2

2

3

3

1

2

2

3

3

Business Process: Breakdown Maintenance

• Time confirmation • Technical completion

• Order settlement • Technical confirmation

(22)

Plant Maintenance - Overview

Maintenance

Order: Putting in Process

Status

'RELEASED'

Order papers

(23)

Plant Maintenance - Overview

 SAP AG 1999

Time Confirmations

Initial screen

Partial confirmation

Final confirmation

Reversal option

Scope

Individual entry

Collective entry

Collective entry using operation list

Overall completion confirmation

(24)

Plant Maintenance - Overview

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

(25)

Plant Maintenance - Overview

 SAP AG 1999

Notification

Planning

Scheduling

Execution

Completion

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 • Time confirmation • Technical completion • Order settlement • Technical confirmation

4

5

2

3

1

(26)

Plant Maintenance - Overview

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

(27)

Plant Maintenance - Overview

 SAP AG 1999

Date / time / reported by Description

Object: Functional location Equipment

Assembly

Material serial number Location data Breakdown / availability Activity Execution factors Activities Dates Task description Tasks Damage location Damage Cause of damage Text Notification items Notification

(28)

Plant Maintenance - Overview

i

i

Object information

Notifications

Maintenance dates

Documents

Links

Breakdowns

Structure list

Processing days

Orders

(29)

Plant Maintenance - Overview

 SAP AG 1999

Select Maintenance Notifications

Find particular maintenance notification Process several maintenance

notifications simultaneously Restrict planning worklist Why ?

Different sorting

Select / delete complete list

Different list fields, internal display variant Display breakdowns graphically

Excel processing Scope Selection conditions Field selection Customizing Functions Notification Notification items Tasks

(30)

Plant Maintenance - Overview

Print Maintenance Notifications

Maintenance

notification

Notification overview Breakdown report Activity report Fax transfer

(31)

Plant Maintenance - Overview

 SAP AG 1999

Notification

Scheduling

Execution

Completion

History

Material usage, orders, notifications, PMIS, usage list

• Technical object • Description • Date • Malfunction • Capacity leveling • Availability check • Order release • Printout

• Planned/unplanned material withdrawal • External procurement • Time confirmation • Technical completion • Order settlement • Technical confirmation

4

5

3

1

Planning

Planning

• Work to be performed• Internal/external resources • Material• Tools

2

(32)

Plant Maintenance - Overview

Maintenance order / notification

Direct creation

of order

Maintenance notification Maintenance order

Creation of order

based on notification

Maintenance item Maintenance order

Automatic generation of

maintenance order

from maintenance item

Maintenance notification Maintenance notification Maintenance notification Maintenance order

Combination of

maintenance notifications

for maintenance order

Maintenance notification Maintenance

order

Entry of order with

subsequent activity report

(33)

Plant Maintenance - Overview

 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

(34)

Plant Maintenance - Overview

Component

assignment

Material

reservation

May May

Availability

check

Goods

issue

Printing

Order

release

Automatic

availability

check

MayMay

Stock Material - Process Flow

(35)

Plant Maintenance - Overview

 SAP AG 1999

Notification

Planning

Execution

Completion

History

Material usage, orders, notifications, PMIS, usage list

• Work to be performed • Internal/external resources

• Material • Tools

• Planned/unplanned material withdrawal • External procurement • Technical object • Description • Date • Malfunction • Time confirmation • Technical completion • Order settlement • Technical confirmation

4

5

2

1

Scheduling

Scheduling

• Order release• Printout • Capacity leveling• Availability check

3

3

(36)

Plant Maintenance - Overview

Stock profile Inward stock movement from purchase order Material withdrawal for cost center

Inward stock movement from internal production

Stock transfer to other plant Plant

stock

Today Requirement date

Safety stock Maximum

ATP quantity

Resource Planning: Availability Check

(37)

Plant Maintenance - Overview

 SAP AG 1999

Maintenance

order

Fax transfer

Job ticket Operation control ticket Pick list Material withdrawal slip Confirmation slip Time ticket Object list

(38)

Plant Maintenance - Overview

Times

Individual entry

Collective entry

Overall completion confirmation

Time sheet (CATS)

Activities

Activity reports

Overall completion confirmation

Confirmation texts

Object changes

Measurement readings

(39)

Plant Maintenance - Overview

•Questions ??

•Contact Details :

mail id :

gthangavelu@darylflood.com

Cell : 469-879-4674

Residence : 972-444-8510

References

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