sap plant maintenance
DESCRIPTION
SAP Plant Maintenance Functional OverviewTRANSCRIPT
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18650 W. Corporate Drive Suite 120 Brookfield, WI 53045 262.792.0200an award winning '2004 Future 50 Company'
Plant Maintenance in SAPA functional perspective
By Gopinath
breaking through barriers to progress
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SAP R/3 - Overview
SAP AG
R
Overview: R/3 Overview and Integration
R/3R/3Client / ServerClient / Server
ABAPABAP
COCOControllingControlling
AMAMAsset MgmtAsset Mgmt
PSPSProjectProjectSystemSystem
WFWFWorkflowWorkflow
ISISIndustry Industry SolutionsSolutions
HRHRHumanHuman
ResourcesResources
SDSDSales & Sales &
Distribution Distribution
PPPPProductionProduction
PlanningPlanning
QMQMQualityQualityMgmtMgmt
FIFIFinancialFinancial
AccountingAccounting
PMPMPlant Main-Plant Main-
tenancetenance
MMMMMaterialsMaterials
MgmtMgmt
System-Wide Concepts
TeamSAP AcademyR/3 Overview &
Integration
R/3 Applications
Support & Services
Getting Started
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3Plant Maintenance - Overview
SAP AG
R
SAP R/3 Modules
Human Resources
Logistics Accounting
Cross ApplicationFunctions
R/3R/3Client / ServerClient / Server
ABAPABAP
FIFIFinancialFinancial
AccountingAccountingCOCO
ControllingControllingTRTR
TreasuryTreasury
PSPSProjectProjectSystemSystem
WFWFWorkflowWorkflow
ISISIndustryIndustry
SolutionsSolutions
MMMMMaterialMaterialManagManag..
HRHRHumanHuman
Resources.Resources.
SDSDSales &Sales &DistribDistrib..
PPPPProductionProductionPlanningPlanning
QMQMQualityQualityManagManag..
PMPMPlantPlant
Maint Maint..
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4Plant Maintenance - Overview
SAP AG
R
SDMM
PP
QAPM
HR
FICO
AM
PSWF
IS
R/3What Is Integration?
Common organizational structures throughoutthe system
Seamless processing of common data betweenapplications
Comprehensive support and reference tools Common reporting features and functionality Object and application linking and overall system
communication
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5Plant Maintenance - Overview
SAP AG 1999
Plant Maintenance is an integral partof the company and has numerouslinks 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
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6Plant Maintenance - Overview
SAP AG 1999
Functional locationsEquipmentAssembliesBills of materialNetworks of technical objects
Maintenance notificationsMaintenance orders
PMIS Plant Maintenance Information System
Maintenance work centers
EQM Technical Data
Task listsMaintenance plans
PRM Preventive Maintenance
WOC Maintenance Processing
CRP Work Centers and Capacity
Structure of Plant Maintenance
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7Plant Maintenance - Overview
SAP AG 1999
Concept of Plant Maintenance
Bills of material
Task lists
CharacteristicsClasses
Equipment /functional locations
Cost recordsCost center
Maintenancework centers
Maintenancenotification
Materialreservation
Materialissues
Maintenanceorder
Capacityload
Timeconfirmation
Purchaserequisition
Maintenancestrategies
Maintenanceplans
Master data
Planning
Order processing
Goods receipt /invoice receipt
Purchase orders /release order
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8Plant Maintenance - Overview
SAP AG 1999
Organizational Structures in Plant Maintenance
General Organizational Units in Logistics
Location-Based Organizational Units
Planning-Based Organizational Units
Maintenance plantFor example, site,building, coordinateFor example, productionarea, plant engineer
Client
Maintenanceplanning plant
Maintenancework centers
For example, foreman,work scheduling
For example, mechanics
Maintenanceplanner groups
Plant section
Location
Plant
Company code
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9Plant Maintenance - Overview
SAP AG 1999
Plant 1000
Cross-Plant Maintenance
Plant 1200 Plant 1300
Workshops
Workshops
Maintenancerequirement
Maintenancerequirement
Planning ofmaintenancerequirements
Maintenancerequirement
Material
Warehouse
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Plant Maintenance - Overview
SAP AG 1999
Maintenance Work Centers
Maintenance work centers
For example:Welding
MetalworkingMechanics
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Plant Maintenance - Overview
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Work Center: Contents
Basic data General data
Capacity data Capacity categories Scheduling
Capacity / pool capacity
Available capacity profile
T i m e
LinksLinks Activity types
Staffing assignment
Staffing assignment
Activity types
Activity types
Work center
Person
Qualification Staffing assignment
Cost center
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Plant Maintenance - Overview
SAP AG 1999
Work Center: Main Functions
Work CenterWork Center
Costingdata
Costingdata
Default valuesfor task lists and orders
Default valuesfor task lists and orders
Schedulingdata and
available capacity
Schedulingdata and
available capacity
1011
CostingCosting
2,724.001,200.00 124.00
4,048.00
2,724.001,200.00 124.00
4,048.00
Task list / orderTask list / orderLead time
schedulingCapacity planning
Lead timescheduling
Capacity planning
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Plant Maintenance - Overview
SAP AG 1999
Technical
Functional
Spatial
Functional location = multi-level, hierarchical structure, organized according to ...
Criteria
Functional Location
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Plant Maintenance - Overview
SAP AG 1999
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?
When is a functional location created?
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Plant Maintenance - Overview
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Automatic Assignment Upon Creation
C1-BBiologicalcleaning
C1C1ClarificationClarification
plant plantC1-M
Mechanicalcleaning
C1-M01Sandtrap
C1-M02Oil/fattrap
C1-B01Pumpplant
C1-B02Filteringstation
Existingfunctionallocations
Newfunctionallocations
C1-M01-2
VentilatorC1-M01-2Ventilator
C1-M02-2Ventilator
C1-B01-1Pump 1
C1-B02-2Filter cell
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Plant Maintenance - Overview
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Example of Functional Location Structure
C1-BBiologicalcleaning
C1C1ClarificationClarification
plant plant
C1-M01-1
Reservoir
C1-M01-2
Ventilator
C1-M01-3Sand
dredger
C1-M02-1
Reservoir
C1-M02-2
Ventilator
C1-M02-3Fat
dredger
C1-B01-1
Pump 1
C1-B01-2
Pump 2
C1-B02-1
Ventilator
C1-B02-2Filtercell
C1-MMechanical
cleaning
C1-M01Sandtrap
C1-B02-1A
Valve 1
C1-B02-1B
Valve 2
C1-B02-2A
Inlet
C1-B02-2BFiltratelevel
C1-B02-2C
Outlet
C1-M02Oil/fattrap
C1-B01Pumpplant
C1-B02Filteringstation
C1-B02-2A/1
Valve 1
C1-B02-2A/2
Valve 2
C1-B02-2C/1
Valve 1
C1-B02-2C/2
Valve 2
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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
Recording of usage times
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Plant Maintenance - Overview
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Equipment Master Record
Equipment master recordEquipment master record
Internal noteInternal note
Documents /Documents /technical drawingstechnical drawings
Multilingual textsMultilingual texts
Equipment usageEquipment usageLocation A
Location B
ClassificationClassificationList
XX
X
XX
XX
Address / partnerAddress / partner
PermitsPermits
Measuring points /Measuring points /counterscounters
0 4 7 10 1 2 3
GeneralGeneral
LocationLocation
OrganizationOrganization
StructureStructure
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Plant Maintenance - Overview
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Bills of Material in Company
Engineering/designbill of material
Costingbill of material
Maintenancebill of material
Productionbill of material
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Plant Maintenance - Overview
SAP AG 1999
Breakdown Maintenance: Business Scenario
For breakdown maintenance, thedata required for the other businessprocesses needs to entered quicklyand easily so that the subsequentsteps can be executed.
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Plant Maintenance - Overview
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NotificationNotification
PlanningPlanning
SchedulingScheduling
ExecutionExecution
CompletionCompletion
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
44
55
22
33
1
22
33
Business Process: Breakdown Maintenance
Time confirmation Technical completion
Order settlement Technical confirmation
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Plant Maintenance - Overview
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Maintenance Order: Putting in Process
Status'RELEASED'
Order papersPut in process
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Plant Maintenance - Overview
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Time Confirmations
Initial screen
Partial confirmationFinal confirmation
Reversal option
Scope
Individual entryCollective entryCollective entry using operation listOverall completion confirmation
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Plant Maintenance - Overview
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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
Close open capacities
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Plant Maintenance - Overview
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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
Cycle for Corrective Maintenance
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Plant Maintenance - Overview
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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
Definition of Maintenance Notification
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Plant Maintenance - Overview
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Date / time / reported byDescriptionObject: Functional location Equipment Assembly
Material serial numberLocation dataBreakdown / availability
Activity Execution factorsActivities
Dates Task descriptionTasks
Damage location Damage Cause of damage
TextNotificationitems
Notification
Maintenance Notification: Structure
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Plant Maintenance - Overview
SAP AG 1999
iiObject information
NotificationsMaintenance dates
Documents
Links
Breakdowns
Structure list
Processing days
Orders
Maintenance Notification: Object Information
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Plant Maintenance - Overview
SAP AG 1999
Select Maintenance Notifications
Find particular maintenance notificationProcess several maintenancenotifications simultaneouslyRestrict planning worklist
Why ?
Different sortingSelect / delete complete listDifferent list fields, internal display variantDisplay breakdowns graphicallyExcel processing
Scope
Selection conditionsField selection
Customizing
Functions
NotificationNotification itemsTasks
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Plant Maintenance - Overview
SAP AG 1999
Print Maintenance Notifications
Maintenancenotification
Notificationoverview
Breakdownreport
Activityreport
Fax transfer
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Plant Maintenance - Overview
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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
PlanningPlanning Work to be performed Internal/external resources
Material Tools
2
Cycle for Corrective Maintenance
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Plant Maintenance - Overview
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Maintenance order / notificationDirect creationof order
Maintenance notification
Maintenance order
Creation of orderbased on notification
Maintenance item
Maintenance order
Automatic generation ofmaintenance orderfrom maintenance item
Maintenance notification
Maintenance notification
Maintenance notification
Maintenance order
Combination of maintenance notificationsfor maintenance order
Maintenance notification
Maintenance order
Entry of order withsubsequent activity report
Creation of Maintenance Orders
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Plant Maintenance - Overview
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Flexibility of order processing
Execution
Period of validity
Object referenceSingle object Object list
Single order Standing order
Internal processing External processing
Characteristics of Maintenance Orders
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Plant Maintenance - Overview
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Componentassignment
Materialreservation
MayMayAvailabilitycheck
Goodsissue
Printing
Orderrelease
Automaticavailabilitycheck MayMay
Stock Material - Process Flow
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Plant Maintenance - Overview
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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
SchedulingScheduling Capacity leveling Availability check
Order release Printout
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Cycle for Corrective Maintenance
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Plant Maintenance - Overview
SAP AG 1999
Stockprofile
Inward stockmovementfrom purchaseorder
Material withdrawalfor cost center
Inward stock movementfrom internal production
Stock transferto other plant
Plantstock
Today Requirement date
Safetystock
MaximumATP quantity
Resource Planning: Availability Check
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Plant Maintenance - Overview
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Maintenanceorder Fax transfer
Job ticket
Operation control ticket
Pick list
Materialwithdrawal
slip
Confirmationslip
Time ticket
Object list
Maintenance Order: Printing
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Plant Maintenance - Overview
SAP AG 1999
TimesIndividual entryCollective entryOverall completion confirmationTime sheet (CATS)
ActivitiesActivity reportsOverall completion confirmationConfirmation texts
Object changes
Measurement readings
Order Completion Confirmation: Times / Activities
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Plant Maintenance - Overview
Questions ??
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