Plant Maintenance in SAP
A functional perspective
By – Gopinath
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
Plant Maintenance - Overview
SAP AG RSAP 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..Plant Maintenance - Overview
R SD MM PP QA PM HR FI CO AM PS WF ISR/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
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
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
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
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
Plant Maintenance - Overview
SAP AG 1999 Plant 1000Cross-Plant Maintenance
Plant 1200 Plant 1300 Workshops Workshops Maintenance requirement Maintenance requirement Planning of maintenance requirements Maintenance requirement Material WarehousePlant Maintenance - Overview
Maintenance Work Centers
Maintenance work centers
For example:
Welding
Metalworking
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
Plant Maintenance - Overview
Work Center: Main Functions
Work Center
Work Center
Costing data Costing data Default values for task listsand 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 4,048.00Task list / order
Task list / order schedulingLead time
Capacity planning
Lead time scheduling Capacity planning
Plant Maintenance - Overview
SAP AG 1999
Technical
Functional
Spatial
Functional location = multi-level, hierarchical structure,
organized according to ...
Criteria
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?
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-M01-2Plant 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
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
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 BClassification
Classification
XList X X X X X XAddress / partner
Address / partner
Permits
Permits
Measuring points /
Measuring points /
counters
counters
0 4 7 10 1 2 3General
General
Location
Location
Organization
Organization
Structure
Structure
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
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.
Plant Maintenance - Overview
SAP AG 1999Notification
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
Plant Maintenance - Overview
Maintenance
Order: Putting in Process
Status
'RELEASED'
Order papers
Plant Maintenance - Overview
SAP AG 1999Time Confirmations
Initial screen
Partial confirmation
Final confirmation
Reversal option
Scope
Individual entry
Collective entry
Collective entry using operation list
Overall completion confirmation
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
Plant Maintenance - Overview
SAP AG 1999Notification
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
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
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
Plant Maintenance - Overview
i
i
Object information
Notifications
Maintenance dates
Documents
Links
Breakdowns
Structure list
Processing days
Orders
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
Plant Maintenance - Overview
Print Maintenance Notifications
Maintenance
notification
Notification overview Breakdown report Activity report Fax transferPlant Maintenance - Overview
SAP AG 1999Notification
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• Tools2
Plant Maintenance - Overview
Maintenance order / notification
Direct creation
of order
Maintenance notification Maintenance orderCreation of order
based on notification
Maintenance item Maintenance orderAutomatic 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
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
Plant Maintenance - Overview
Component
assignment
Material
reservation
May MayAvailability
check
Goods
issue
Printing
Order
release
Automatic
availability
check
MayMayStock Material - Process Flow
Plant Maintenance - Overview
SAP AG 1999Notification
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 check3
3
Plant Maintenance - Overview
Stock profile Inward stock movement from purchase order Material withdrawal for cost centerInward stock movement from internal production
Stock transfer to other plant Plant
stock
Today Requirement date
Safety stock Maximum
ATP quantity
Resource Planning: Availability Check
Plant Maintenance - Overview
SAP AG 1999
Maintenance
order
Fax transferJob ticket Operation control ticket Pick list Material withdrawal slip Confirmation slip Time ticket Object list