pm key user presentation- harith senarath/janaka pathmendra
TRANSCRIPT
Plant Maintenance Key User Presentation
SAP - An E.R.P. Package
Contents of PM Module
Benefits of PM Implementation
ERP OverviewERP Overview
What is an ‘E.R.P.’ ?
Why ‘E.R.P.’ is needed ?
Who are Global ‘E.R.P.’ Vendors?
What is ‘SAP’ ?
What is ‘Client Server’ Technology ?
General QuestionsGeneral Questions
E.R.P. : ENTERPRISE RESOURCE PLANNINGFor managing 4M’s of enterprise EFFECTIVELY.EFFECTIVELY.
MATERIAL MATERIAL
MACHINE MACHINE
MEN MEN
MONEY MONEY
What is an ERP?What is an ERP?
A Standard Software Package taking care of all
the needs of an enterprise.
‘E.R.P.’ integrates business processes across
the whole company.
‘E.R.P.’ provides & helps the enterprise to
adopt latest technology & international
business practices with minimum ease.
Why ERP?Why ERP?
Examples of Vendors Providing ERP Packages
SAP BAAN JD-Edwards Marshall People-soft
ERP VendorsERP Vendors
Systems, Applications, Products in Systems, Applications, Products in Data ProcessingData Processing
Walldroff, Germany.
SAP Stands for? SAP Stands for?
R/3R/3Client / ServerClient / Server
COCO
AMAM
PSPSWFWF
ISIS
MMMM
HRHR
SDSD
PMPM
PPPP
QMQM
FIFI
Integration Of PMIntegration Of PM
Overview Plant Maintenance Features of SAP PM Master Data Preparation Plant Maintenance Business Process Report Requirement Critical Success Factors
OutlineOutline
Overview Of Plant Maintenance
Definition: Maintenance is an action required to preserve or to retain the health of equipment.
Importance: Because of the increase in automation and the resulting high fixed costs of operational systems, plant maintenance plays a decisive role in the success of any business. Production system need to be available 24 hours a day in order to guarantee cost effective distribution of fixed cost
Plant Maintenance Plant Maintenance
Materials Management Finance / CostingMaterial master Accounting Service master Order settlementEquipment Bill of material Cost centerSpare parts planning Activity pricingInventory management Purchase of materials Services and contracts
Quality Management Asset ManagementInspection of parts Equipment and Asset linkCalibration
Production Planning Human ResourcePRT Scheduling Man Power Capturing
Plant Maintenance IntegrationPlant Maintenance Integration
The operational systems are managed using functional locations, equipment & sub-equipment.
Preventive maintenance and inspection plans which are done at a regular interval are released at a scheduled point of time.
Malfunctions and other direct requirements are entered directly as maintenance notification and forwarded to the respective workshop responsible for processing.
Maintenance tasks are carried out using maintenance orders.
Cost captured in the maintenance order is settled against the respective production cost center.
The completed maintenance notifications & orders form the basis for creating maintenance history.
Plant SupportPlant Support
Malfunction, RequestActivity
Malfunction, RequestActivity
Maintenance notificationwhatwhen wheretechnical infobreakdown
Order creationPlanning of task
whowhen, how longwhich stepsaccount assignment resources
Executionwithdrawalutilitiesprocurementwork steps
Technical informationmalfunctioncausesobjects affectedactivity
Maintenance history
Completion
Taskrequested
1111
Order
Confirmation
Closing
22223333 4444
5555
66667777
8888
Operation Maintenance planning Maintenance workshop
Fundamental Maintenance Processing StepsFundamental Maintenance Processing Steps
Master Data Preparation
MASTER DATA
MAINTENANCE PLANNING
NOTIFICATION PROCESSING
PM ORDER PROCESSING ( RUSH / UNPLANNED )
ORDER SETTLEMENT
PM PROCUREMENT & SPARES MONITORING
HISTORY & ANALYSES
ContentsContents
Master Data
Functional Location Equipment Catalog Profile (Object, Cause & Damage) Check List (Task List) & Plan Equipment Sub-Equipment Relation Equipment BOM Measuring Points & Counters Process Instruments for Calibration
Master Data ProcessingMaster Data Processing
Technical Object Management Functional location Equipment master data Permits Partner & Addresses Object link master data
Bill Of Material Location specific BOM. Equipment BOM. Assembly / Material BOM.
Master RecordsMaster Records
PM Work-Center.
PM Task-List -> Service sheet Functional location Equipment General
Measurement Point & Counter
PM Catalogues.
PM Material Master
External Service
Master Records Contd..Master Records Contd..
A functional location is an element in a technical structure, representing an area of a Plant at which Equipment/s can be installed.
Advantages of structuring functional location
1. Identifying the locations via codification logic.2. Relationship of Functional Location with Orgnization3. Identifying the hierarchical position in structure4. Generating the reports.
Functional LocationFunctional Location
Multilingual textsInternal note
Equipment usageClassification
DocumentsPartner/AddressesMeasuring points
Permits
Equipment master record
PM dataLocation data
Production resources/tools dataSerial number data
General Data
Equipment MasterEquipment Master
Advantages of BOM
MATERIALS PLANNING
MATERIAL/SPARES PLANNING
LOCATING MALFUNCTIONS
Work CentersWork Centers
It defines the group of workmen's or single person or machine or multiple machines responsible for carrying out the activity. This also indicates who is supposed to carry out the maintenance. It can be even machines.
PLANT MAINT. HISTORY
PM Order
•Costs•Materials•Operations
Equipment Plant Area(Functional location)
Notification
MAINTENANCE HISTORY
Notification historyOrder historyUsage list (Instll.Period)
Master Records•Description of Notif.•Time data,B/D Hrs.•Machine/ Object data•Fault location,Damage•Causes, Action taken
•Text,Object
PM Business Process
Preventive Maintenance (Time / Performance Based)
Breakdown MaintenanceMaintenance Request / ActivityRefurbishmentCalibration of process instrumentsCapital Investments
Key Business ScenarioKey Business Scenario
Scheduled Maintenance
Unscheduled Maintenance
Maintenance Plan
SchedulePlan
Create PM Orders
Adjust planned dates if requ’d
Maintenance Notification
Manually create orders
Short term planning in order
Release order
Execute maintenance
Maint operation completion confirmation
Technically complete order
Record technical data in notification
Complete notification
Settlement
Functional Flow SummaryFunctional Flow Summary
NotificationNotification
OrderOrder
ControlControl
ProcessingProcessing
CompletionCompletion
History Material usage, orders, notifications, PMIS, usage list
History Material usage, orders, notifications, PMIS, usage list
• Technical Object• Description
• Date• Malfunction
•Tasks to perform• Resources int./ext.
• Components• Tools
• Availability check• Release order• Print papers
• Material withdrawal planned/unplanned• External procurement
•Time confirmation•Techn.completion
• Order settlement• Techn. confirmation
44
55
22
33
11
Steps In PM ProcessingSteps In PM Processing
Purchaserequisition
Completionconfirmation
Maintenance orderMaintenance order
Op. 10: Internal processing
Op. 20: External processing
Service confirmationGoods receipt
Invoice receipt
Purchase order
Activity costs
Activity costs
Material Consumption
External Processing FlowExternal Processing Flow
Creation ofservice
specifications
Determinationof requirements
Serviceacceptance
Invoiceverification
Serviceentry
POmonitoring
Orderingprocess
Vendorselection
Quotationentry
Bid invitation
- User department- PM Plant maintenance- PS Project system
PO Invoice
?=
RFQ
Procurement StepsProcurement Steps
Maintenance orderMaintenance order
Internal Processing
operation 10: ME 3 hoursoperation 20: EL 1 hour
External processing
operation 30: EXT 1 hour
Material
2 pcs. Material ABC
Costs
Internal Processing: Rs 500.00
External Processing: Rs150.00
Material: Rs300.00
Total: Rs950.00
Costs
Internal Processing: Rs 500.00
External Processing: Rs150.00
Material: Rs300.00
Total: Rs950.00
Cost ProcessingCost Processing
Plant wise viewMaintenance Group wise viewPlanner Group wise viewEquipment wise viewFunctional Location wise viewFinancial Period wise viewPlan vs Actual cost
Cost AnalysisCost Analysis
TYPES OF PM PLANNING
2) Counter based maintenanceA - With maintenance strategyB - With multiple counter plan
1) Time based planningMonthMonth
P1 x xP1 x xP2 x x x x x x xP2 x x x x x x x
kilometerkilometerP1 x xP1 x xP2 x x P2 x x
PM Reports
List of Breakdown Notifications( Daily & Monthly)
Equipment Breakdown HistoryMTTR / MTBR / MTBFDamage AnalysisManufacturer wise Breakdown Analysis
Break Down ReportBreak Down Report
Preventive maintenance schedulePreventive maintenance Performance
summaryPreventive maintenance feed back
summary(check list)Graphical Scheduling OverviewMaterial where used ListCost Analysis
Preventive Maintenance ReportPreventive Maintenance Report
Planned (Preventive )Maintenance Cost
Un-Planned (Breakdown) Maintenance
Maintenance Cost ReportMaintenance Cost Report
Goods Receipt Goods IssueSpare consumption through
Maintenance Order(261 Mov. type)Consumption through direct issue to
cost center(201 Mov. type)Consumption actual vs. planned budget
Material where used List
Spare Parts ReportSpare Parts Report
Cost at Work Center level
Cost of Internal Activity, External Services & Spares
Actual Cost Vs Planned Budget at work center level
Repairs & Maintenance BudgetRepairs & Maintenance Budget
Condition of a particular Equipment/Functional Location can be managed by Condition Based Monitoring by using Measuring Points & Counters which is created against Equipment/Functional Location (Trend Analysis), Characteristic Vs Time
The Preventive Maintenance (Internal / External) schedule can be generated with the help of counters ,In case of External Processing Purchase Requisitions are generated.
Condition Monitoring ReportCondition Monitoring Report
THANK YOU