pm module ppt

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“Your Trusted IT Partner”

Process Excellence

SAP PLANT MAINTENANCE

Click to edit Master title styleSAP R/3 ERP

Accounting Area Financial accounting (FI) Controlling (CO) Asset Accounting (FI AA)• Human Resources HR• LogisticsProduction Planning (PP)Materials Management (MM)Sales and Distribution (SD)Quality Management (QM)Service Management (SM)Plant Maintenance (PM)

Click to edit Master title styleSAP Organizational Structure

Click to edit Master title stylePM Overview

Plant Maintenance Introduction Plant Maintenance OrganizationTechnical ObjectsBreak Down MaintenanceCorrective MaintenanceRefurbishment Of Spare PartsPreventive MaintenanceWork Clearance Management

Click to edit Master title stylePlant Maintenance Introduction

SAP Plant Maintenance automates the process of performing facility repair and maintenance requests.

For example,. SAP records a problem that is reported, labor and materials are planned, costs are recorded, and then costs are settled

Plant Maintenance operates the overall maintenance business processes and functions allows a maintenance organization to:

Identify, document, and correct failures and degradations of any assets for which they have responsibility.

Click to edit Master title stylePlant Maintenance Process Flow

Click to edit Master title stylePlant Maintenance Process Flow

PM Process Flow

Maintenance Order

Notification

Plan

Control

Complete

Schedule

Execute

Click to edit Master title stylePlant Maintenance Process Overview

Click to edit Master title stylePlant Maintenance Organization

Plant Maintenance Organization1) Overview of Processes and Available Solutions

Lifecycle of technical Asset• Investment Planning• Projects Definition• Selection of Vendor• Plant Maintenance• External Procurement• shutdown


Plant Maintenance OrganizationCharacteristics

Classes

Equipment/Functional Locations

Tasks List

Bill of Material

Maintenance Work Centers

Cost Center

Cost Records

MaintenanceStrategies

Maintenance Plans

Purchase Order/Release Order

Master Data

Planning

Order ProcessingPurchase Requisition

Time Conformation

Capacity Load

Maintenance Order

Material Issue

Material Reservation

Maintenance Notifications

Goods Receipt/Invoice Receipt


2) User InterfaceVarious methods that user connects to SAP Power User Sporadic User

3) Organizational Levels In Plant Maintenance Depending on the Company Structure

Maintenance planning is either of following type

• Plant-Based (Decentralized)• Cross-Plant (Centralized)


3) Organizational Levels In Plant Maintenance

Analyze Existing Company StructureDefine Maintenance Plants/Planning PlantsAssign Planning Plant/Work Center Maintenance planner groups are assigned to planning

plantsMaintenance work centers are assigned to

maintenance plant

Click to edit Master title stylePlant Based Organization Structure

Plant Based Organizational Structure


Maintenance Plant & Planning Plant The plant, at which the operational systems of a

company are installed, is called the maintenance plant.

If the maintenance work is planned at this plant, the maintenance plant is also the maintenance planning plant.

A maintenance planning plant is the organizational unit in which maintenance requirements are planned.


Maintenance Planning Plant Structure


Planner Group The planners within a maintenance planning plant

are defined by maintenance planner groups.

The units of capacity in Plant Maintenance are managed as maintenance work centres in the PM system.

The maintenance work centres are usually assigned to the maintenance planning plant.

Click to edit Master title styleWork Centers

Work center is an organizational unit where work is carried out.Ex: Machine, Group of machines or group of persons.

Work centres belong to the master data in PM and provide the capacity required to perform a task.

The basic data contains general data such as work centre category, description, responsibility, and usage

Work centers can be linked to: Cost Centers, Positions, People

Click to edit Master title styleWork Centers

Functions: Costing : To determine the costs of an internal

activity by a product unit Scheduling : To determine the dates when

operations should be performed. Capacity Planning : The capacity requirements for

the operations in the orders are determined

Click to edit Master title styleTechnical Objects

Technical Objects1) Functional Locations Functional locations are elements of a technical structure . We create

Functional Structures if we want to represent systems or operational structures within our company according to functionality.

Create functional locations hierarchically, and can also structure them based on the following criteria:

Spatial Ex: Buildings. Technical Ex: Press or Press Hydraulics Process-related Ex: Polymerization,.

Click to edit Master title styleFunctional Location Creation


Functional Locations

Functional Location Structure



The main Aim of creating Functional Locations is to Structure a technical System or building into units that are relevant to Plant maintenance.


Click to edit Master title styleFunctional Location

Structure Indicator The identification for functional locations is created using the structure indicator. The structureindicator consists of two input fields:

Edit mask : The edit mask is used to control which characters may be used for identification (letters, numbers, or both) and how these characters are grouped together or split.

Hierarchy levels: The hierarchy levels are used to define which level ends at which character and how many hierarchy levels the structure may contain.


Functional LocationsA functional location can be identified using a maximum of 40 characters (= maximum length of the edit mask).


Click to edit Master title styleEquipment

2) Equipment A piece of equipment could be part of bigger

technical structures or independent Piece of equipment is usually represented as single

object(Ex: Pumps, motors, vehicle) for which maintenance tasks should be performed.


Create an equipment master record for a technical object if: You need to manage individual data for the object

Breakdown, prepared or preventive maintenance task are required for an object and must be recorded

Technical data for this object must be collected and evaluated over long periods of time

The costs of maintenance tasks for this object are to be monitored

Record the usage time of this object at functional locations


Functional LocationsThe time-based data can be used to monitor a piece of equipment dynamically, that is, track changes to the equipment over a specific period of time.

Purpose of Equipment


2) Equipment This role contains all the functions that you require to

process equipment.Equipment Activities in Plant Maintenance (PM) Creating a piece of equipment (generally, as

production resource/tool, fleet object) Collective entry for equipment Changing a piece of equipment Data transfer from equipment Taking up data transfer



Bills of material are used for different purposes. The usage depends on the enterprise area

Bill Of Material

Click to edit Master title styleBill Of Material

3) BOM The Production Bill of Materials represents a

finished product (parent )made up of different inventory components (children). During the production process, you turn the components into the finished product.

Components in the production bill of materials are physical items (for example a screw, a wooden board, a measured quantity of lubricant or paint), or virtual objects (one work hour)


3) BOM The engineering/design bill of material includes all

the elements of the product (from an engineering viewpoint) and contains the technical data. It is usually not dependent on the order.

The costing bill of material reproduces the product structure and forms the basis for automatic determination of the material usage costs for a product. Items that are not relevant for costing are not included in this bill of material.


3)BOM The maintenance bill of material has three important

functions: It only contains items relevant to Plant Maintenance.

Structuring of the object : The structure of an object should be displayed as clearly as possible from a maintenance viewpoint.

Spare parts planning in the order: If a bill of material exists for a technical object, it can be used during the planning process of a maintenance order for the purpose of spare parts identification and planning.

Spare parts planning in the task list: Spare parts can be planned in the task list based on a bill of material


3)BOM Instead of a uniform bill of material, these areas use

"their own" bill of material with area-specific data (for example, production).

They only evaluate bills of material containing area-specific data. This results in a targeted bill of material explosion, whereby only the area-specific data is made available.


3) BOM Categories of BOM’s are

Material BOM Equipment BOM Functional Location BOM A material BOM is a bill of material that is first

created for a material independently of a technical object. To do this, material creation is must.

Create a material BOM for the material



Bill Of Material

Click to edit Master title styleBreak Down Maintenance

Break Down Maintenance Using this business process we can report, perform,

and document maintenance tasks that arise suddenly. All the resources used, costs, and technical details of

the maintenance task are recorded centrally and can then be evaluated.

Usually this process is relevant if a technical asset exhibits a defect, for example, if a pump is leaking or a printer is not printing properly.


Diverse employees can create a maintenance notification to report the defect.

The responsible maintenance technician receives these notifications in his or her work list and makes the necessary repairs. Process Flow1.Notification & Scheduling2. Execution3. Completion


Break Down Maintenance

Break Down Maintenance Flow



Create / process notification Generate work list for notifications Create / process order Confirm time Modify technical object structure Process Execution complete order

Click to edit Master title styleRefurbishment Of Spare Parts

Refurbishment of spare parts: In a company ,Defective or warn-out spare parts in storage

should be refurbished.

Refurbishment Process Pre Requisites for Refurbishment in Material Master Separate Evaluation Refurbishment Order Check the effects of refurbishments on stock value



Refurbishment Process


Refurbishment of spare parts: During the refurbishment process, equipment is

maintained by a team of maintenance planners, maintenance technicians, and store persons.

After a maintenance technician has determined and replaced the defective equipment, the maintenance planner posts the defective item to stock

After planning has been posted, the maintenance planner creates and releases a refurbishment order for the given items.


Refurbishment of spare parts: Calculated the time and material resources are neede

for the refurbishment. The order is conformed and Completed.

The stock value changes dynamically according to the condition of the items, with the price of a refurbished item covering all internal and external material and labour costs spent on refurbishing.

Click to edit Master title stylePreventive Maintenance

Preventive Maintenance Preventive maintenance work is performed to ensure

optimal operation of equipment & avoid costly unplanned equipment failure or shutdown.

To keep down times and maintenance costs minimum, the technical systems are inspected and maintained regularly

Preventive Maintenance Can be followed by 3 Factors Time Based Performance Based Condition based


Preventive Maintenance Time Based In time-based preventive maintenance, the

maintenance tasks are planned and performed depending on the time-dependent intervals determined. (Ex ,Every 6 months)

Performance-Based (Performance) This preventive maintenance, tasks are triggered

after a specific performance level has been reached(Ex, Every 10,000 kms)


Preventive Maintenance Condition Based

If the service life is exhausted or if the asset is no longer in good enough condition to perform its service to the required quality

Then the service life must be restored through maintenance or repair work. These maintenance tasks are generated and performed based on a certain asset condition.



Preventive Maintenance

Preventive Maintenance


Task Lists In the company, all inspection and maintenance tasks

that must be performed at regular intervals are defined in maintenance task lists. Task list header data

Maintenance Planning Single Cycle Plan (Same activity at regular

intervals) Strategy (Maintenance work performed in

different cycles)Maintenance strategy


Preventive Maintenance Process in Detail Create / process notification Generate work list for notifications Create / process order Plan and schedule order Perform work clearance management Confirm time Perform evaluations in plant maintenance information

system (PMIS)

Click to edit Master title styleCorrective Maintenance

Corrective Maintenance Maintenance actions carried out to restore a defective

item to a specified condition

5 Phases of corrective Maintenance Entering Requirement(Notification) Planning Orders with Operations and Materials (Planning) Monitoring the cost (Control) Performing the tasks(Execution) Completing the Order and Notifications.(Completion)



Corrective Maintenance



ACTIVITIES are work performed for Notifications.Importent for inspection, they prove that certain tasks have been performed.TASKS: Describes the Activities that still have to be performed.(Also used for planning purpose)




Corrective Maintenance5 Phases of corrective Maintenance

Entering Requirement(Notification) Planning Orders with Operations and Materials

(Planning) Monitoring the cost (Control) Performing the tasks(Execution) Completing the Order and Notifications.

(Completion)


Corrective Maintenance Notification: is the technical object contains the

description about the malfunction or requirement Malfunctions and other requirements are recorded in

notification, notifications can be accessed and processed via a list

Planning : In this phase orders are created and planned on the basis of the reported requirements. Planning compasses the Work to be performed , and the material required.


Corrective Maintenance Control: In this phase order runs through the different

phases such as material availability check, capacity planning.

Execution: Order is executed in this phase, Required material for the order is withdrawn.

Completion: Technical Conformation and Technical completion.

Click to edit Master title styleWork Clearance Management

Work Clearance Management This business process to enforce all safety measures

that must be enforced before inspections, repairs, or preventive maintenance work are performed.

Maintenance Workers operate in a dangerous Environment(Ex: High Voltage, Radio Activity).

The WCM component helps company to control and monitor safety measures.

Helps to ensure and secure working conditions for plant maintenance employees.



Work Clearance Management


Work Clearance Management is integrated into the Plant Maintenance (PM) component



WCM Process Flow (1)


Order

Work Clearance Application

Work ClearanceDocument


Create Order

Plan Order/ Request Tag Out

Specify Object containing Tag out/Lockout

Approve and Perform Tag out/Lockout

Click to edit Master title styleWork Clearance Management

Work Clearance Management Lockout-Tag out (LOTO) or lock and tag is a safety

procedure which is used to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work

Work Clearance Document: This document contains a detailed description of lockout / tag out .



WCM Process Flow (2)


Release Order

Work Clearance Application


Order Completion

Release Order Determined

Completing Tagging

Perform Un-tagging

Technically Completing Order


QUERIES ?


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