SAP Plant Maintenance Business Blueprint

Vedanta Alumina Limited Plant Maintenance Page 1 of 1
SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3
SAP R/3 IMPLEMENTATION

BUSINESS BLUEPRINT
Plant Maintenance
Prepared by Checked by Reviewed By Signature Approved By Signature Date

Mr. Krishna Mr. Swain
Vishal Rathore Pinaki Roy Mr. Coumar Mr. Kanada 24.01.2006
Mr. Manna
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CONTENTS
OBJECTIVE OF BUSINESS BLUEPRINT PHASE 3
SCOPE OF BPBP DOCUMENT 6
PLANT MAINTENANCE IN SAP - OBJECTIVE 7
SECTION I 8
SCOPE OF PLANT MAINTENANCE MODULE IN VAL 8
SECTION II 11
ORGANIZATION STRUCTURE 11
SECTION III 29
TO-BE PROCESSES 29
LIST OF REPORTS 82
SECTION IV-APPENDIX 86
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OBJECTIVE OF BUSINESS BLUEPRINT PHASE
This document is the outcome of the As-Is study, Discussion at Training and during the To-Be process and business process requirement analysis
for the Vedanta Alumina Limited.
Based on this As-Is coupled with inputs from the core team members during To-Be discussion, we arrived at the Business Processes, which are
incorporated in the Business Blue Print. The aim of this document is to map the best business processes related to the Plant Maintenance module
in SAP ECC 5.0. This document is to be studied by core team members & process owners from Vedanta Alumina Limited. The preparation of this
document is an essential precursor to prototyping and testing. The development work will start once process owners approval for this Blue Print is
obtained followed by a corporate presentation to the senior management team, Vedanta Alumina Limited.
This document will be used for configuring Plant Maintenance module in SAP implementation. Document is based on discussions/presentations
between representatives of VAL & PWC. In other words it contains
1. SAP Organization Model in context of existing business scenario and future requirements/issues as envisaged by VAL.
2. Mapping of business processes/issues brought forward by PwC & VAL, with SAP functionality
3. Gaps & issues emerged during the discussion between VAL & PwC
4. Business Process Flows mapped in SAP as per the scope defined.
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5. Closure of Mapping Phase and start of Piloting Phase of implementation
A pictorial presentation of complete SAP implementation is depicted in the following page:
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SCOPE OF BPBP DOCUMENT
The objective of this Blue Print presented to the Project Sponsor is to document the following:
a) Business Requirements of VAL that need to be translated into SAP.

This has been prepared by SAP consultants team members on the basis of As-Is document, factory visit & discussions between PwC
SAP consultants and VAL core team members.
b) SAP Gaps as identified by PwC Team w.r.t. The present scope of implementation and Business Requirements of VAL.
c) Details of SAP New Business Process description supported by Process Flow diagram w.r.t. Different SAP process indicating the desired To be
Processes.
In order to bring the clarity and better understanding, the document has been divided in five sections:
SECTION I : Scope of SAP Plant Maintenance module for the project
SECTION II : Organization structure
SECTION III : Master Data Management, As-Is/ To-Be Business processes, and Gaps identified for business processes as per SAP.
SECTION IV: Appendix-Process Flow Diagrams.
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Plant Maintenance in SAP - Objective
To have Reliable Equipments with low MTTR and high MTBF
To have Predictive and Condition based plans that help to improve equipment availability.
To eliminate repetitive breakdowns and thereby reduce wastage of valuable resources
To have a Preventive Maintenance Plan in place that helps to maintain Equipment Health.
To eliminate the need to pull out data from different systems for reporting purposes.
To draw a long-term plan for Spares requirement and also help in Budgeting.
These objectives will be obtained by
By detailed analysis of downtimes and designing a Corrective Action Plan based on this analysis.
By having up to date cost figures (Plant-wise/Location-wise/Equipment-wise) for better maintenance decision-making
By analysing usage data on components and services related to maintenance.
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SECTION I
Scope of Plant Maintenance Module in VAL

PARTICULARS ALUMINA POWER
Master
1.1 General Master Records
1.1.1 Material Master X X
1.1.2 Material BOM X X
1.1.3 Work Center X X
1.1.4 Service Master X X MM
1.2 Plant Maintenance
1.2.1 Technical Objects (Structuring of Technical Systems) X X
1.2.2 Measuring Points & Measuring Documents X X
1.2.3 Warrantees X X
1.2.4 Permits X X
1.2.5 Task Lists X X
1.2.6 Maintenance Strategy X X
1.2.7 Maintenance Plans X X
Business
2.1 Plant Maintenance
2.1.1 Breakdown/Routine Maintenance Processing X X
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2.1.1.1 Notification X X
2.1.1.2 Order X X
2.1.1.3 Material Movements X X
2.1.1.4 Completion Confirmation X X
2.1.2.5 Confirmation of external services through service sheet X X
2.1.1.6 Settlement and Completion X X
2.1.1.7 Evaluations: Information System X X
2.1.2 Preventive / Shut Down Maintenance Processing
2.1.2.1 Maintenance Planning X X
2.1.2.2 Worklist X X
2.1.2.3 Notification X X
2.1.2.4 Deadline Monitoring X X
2.1.2.5 Order X X
2.1.3 Refurbishment Processing in Plant Maintenance
2.1.3.1 Order X X
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2.1.4 Development/Improvement/Re-Design Orders X X
2.1.5 Calibration Orders X X PM/QM
2.2 Inventory Management
2.2.1 Goods Movements
2.2.1.1 Reservation X X
2.2.1.2 Purchase requisition MM
2.2.1.3 Goods Receipt MM
2.2.1.4 Stock Transfers / Trans. Postings MM
2.2.1.5 Goods Issue X X
Cross-Application Components
3.1 Classification System
3.1.1 Characteristics X X
3.1.2 Classes X X
3.1.3 Classification X X
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Section II
Organization Structure
Plants
The plant is an operating area or branch within a company. The plant is assigned to a single company code. A plant has its own material master
data. You can maintain data at plant level for the following views on a material master record in particular: MRP, Purchasing, Storage, Work
scheduling, Production resources/tools, Forecasting, Quality management, Sales, Costing.
As per discussion with Finance & Materials, there will be only four Company Codes and four plants will be created which may be as follows:
VAL Alumina 1000

VAL Power 2000
VAL Smelter 3000
VAL JV 4000
Out of this, the VAL Alumina Plant (1000), VAL Power Plant (2000) will have complete PM Implementation while the VAL smelter Plant (3000) and
JV (4000) will only have PM basic organization structure.
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Maintenance Plant
In Plant Maintenance, a distinction is made between the organizational units "planning plant" and "maintenance plant".
Maintenance plant
In a maintenance plant, you can manage technical objects and main work centers.
Planning plant
In the planning plant, maintenance task lists are defined for the respective maintenance plants, material planning is carried out on the basis
of bills of material in task lists and orders, maintenance plans are managed and scheduled, maintenance notifications are created and
maintenance orders can be handled.
With discussion for the Organization Structure for Maintenance Planning, it has been decided to follow the based on the Material Management
Plant Code. Since maintenance Planning is independent of all four plants, hence there will be four maintenance planning plants in Plant
Maintenance Organization Structure. They are as follows:
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MAINTENANCE
DESCRIPTION
PLANT
1000 VAL Alumina Maintenance Plant
2000 VAL Power Maintenance Plant
3000 VAL Smelter Maintenance Plant
4000 VAL JV Maintenance Plant
MAINTENANCE
DESCRIPTION
PLANNING PLANT
1000 VAL Alumina Maintenance Planning Plant
2000 VAL Power Maintenance Planning Plant

3000 VAL Smelter Maintenance Planning Plant
4000 VAL JV Maintenance Planning Plant
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Locations
A location is the physical location to identify where the equipment lies. This data helps the Plant Maintenance person to identify where the
equipment is located. Here location, plant section, room number etc. can be mentioned.
Proposed locations for Vedanta Alumina Limited are as follows:
For Alumina Plant (1000)
Location DESCRIPTION
RED Red Area

WHT White Area
UTL Utilities
NPA Non Plant area
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For Power Plant (2000)
TGU Power Generation
BLR Steam Generation

BOP Balance of Plant
For Mining Plant (4000)
MIN Mining
CRG Crushing
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Planner Group
Planner groups or maintenance planning groups must be defined separately for each planning plant.
Depending on the size and structure of your company, a maintenance-planning group may be an individual department (for central work
preparation), a group of skilled craftsmen or a workshop.
Every piece of equipment and functional location can be allocated to a maintenance-planning group.
Maintenance planning groups can also be used for evaluation purposes.

In Vedanta Alumina Limited we have identified FOUR planner groups for each plants
For Alumina Plant (1000)
Planner Group DESCRIPTION

101 Mechanical Planner Group
102 Electrical Planner Group

103 Instrumentation Planner Group
104 Civil planner Group
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For Power Plant (2000)
202 Electrical Planner Group

203 Instrumentation Planner Group
For Mining Plant (4000)

Electrical & Instrumentation
402
Planner Group
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Functional Location category
Functional Location Category to be used M Technical System Standard
Functional Location Structure Indicator
We shall be using the following Structure Indicator for Functional Location Labelling:
STRUCTURE
DESCRIPTION STRUCTURE
INDICATOR
VAL01 Indicator for Alumina Plant NNNN--AAA-AAA-XXX-XXXX-XXXXX
VAL02 Indicator for Power Plant NNNN- AAA-XXX-XXX-XXX-XXX
VAL03 Indicator for Mining Plant NNNN- AAA-XXX-XXX-XXX-XXX

(A- Alpha, X- Any character, N-Numeric)
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Example:
1000-RED-DIG-TR0-DIGV-DIG01
1000 Vedanta Alumina Plant

DIG Digester Area
TR0 Train 0 Area
DIGV Digestion Vessel
DIG01 Digester 01
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Equipment Categories and Equipment Codification
Equipment Categogy for all the equipment will be used as M
It has been decided that the Equipment Code will be Externally generated for easy identification and the logic for that code will be
XX XXX NNNN
Main Group Sub-Group Number
Spare Parts / Assemblies / Components codification
All the spare parts, assemblies, components, consumables for maintenance will be defined as material in SAP for taking them in inventory and the
material code will be externally generated. Logic for the material code is
XX XX XXX XXXXX
Major Group Sub Group Sub- Sub Group Material No
The codification is external.

12 digit codification, split as mentioned above.
It is going to be all numeric
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1. For bearings, the codification will be strictly with the engineering department.
2. Flag in the system for insurance spares.
3. Flag for the regular inventory items.
4. Flag for the value capture of all the materials.
5. For initial project spares, value will be taken as zero and split valuation will be used for it.
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Technical Object Types

This implies a division of a technical object for precise description.
All equipments at VAL would be categorized into various Technical Object Types. An indicative list of technical objects is given below.
Alumina Plant
Technical Object Technical Object Technical Object
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Power Plant
Technical Object Technical Object Technical Object
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Catalog Profile
Combination of code groups, which determine from a functional viewpoint, which code groups can be used for a particular technical object.
The following catalogs would be used for VAL. Common catalog profile will be used for different technical object types.
n Coding - D
n Object parts B
n Problem/Event Codes 4
n Cause Codes 5
n Activity Codes A
We shall be using common catalog profile for all equipments. Details of the catalogs would be maintained as follows:
Coding: Coding of breakdowns as Serious/Semi-serious/Normal
Object Parts: All critical Mechanical and Electrical parts would be configured for each of the technical object types defined.
Problem/Event Codes: All problems that normally occur or might occur would be listed for each type of Technical Object.
Cause Codes: All probable causes of the events/problems listed above would be configured for each technical object type.
Activity Codes: The normal activities (generic) carried out for attending to the problems would be configured here.
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Example:
Technical Object Type : Pump
Object Parts Problems Causes Activities
Impeller Impeller Broken Improper Cleaning Cleaned
Bearing Impeller Jammed Lubrication Failure Machined
Casing Bearing Damaged Life Expiry Rewinding Done
Shaft Abnormal Sound Impeller nut Loose Reset
Pressure Low Misalignment Replaced
Shaft Damaged
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Notification Types
Various Notification Types would be configured in the System to take care of the various types of job requirements.
NOTIFICATION TYPE DESCRIPTION
M1 Maintenance Request (Predictive w/o production loss)

M2 Breakdown Report (Breakdown Maintenance with production loss)
M3 Activity Report (Preventive Maintenance)
M5 Improvement (Modification/Development/Re-Design) Notification
M6 Safety Notification
M7 Shutdown Notification
M8 Calibration Notification
M9 Workshop Notification
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Maintenance Order Types

Seven different types of Maintenance orders will be defined for the various types of maintenance/repair activities to be carried out.
MAINTENANCE ORDER TYPE DESCRIPTION
PM01 Maintenance order w/o production loss

PM02 Breakdown order with production loss
PM03 Preventive maintenance order
PM04 Re-furbishment Order
PM05 Improvement (Modification/Development/Re-Design) order

PM06 Safety Order
PM07 Shutdown Order

PM08 Calibration Order
PM09 Workshop Orders

PM10 Annual Maintenance Contracts
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Assignment of Notification Types to Order Types
Notification type Order type
M1 PM01
M2 PM02
M3 PM03
M5 PM05
M6 PM06
M7 PM07
M8 PM08
M9 PM09
There will be no notification for refurbishment orders &
Annual Maintenance Orders.
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SECTION III
To-Be Processes
Plant Maintenance Processes
The Business Blue Print is divided into various sections as defined by the different processes as discussed during to-be and Expectation from SAP.
These processes are:
Routine/Predictive Maintenance
Breakdown Maintenance
Preventive Maintenance (based on duration and measuring point)
Refurbishment Spares
Improvement / Development / Modification / Re-design Maintenance
Shutdown Maintenance (Planned maintenance)
General Maintenance (to be done through maintenance request)
Annual Maintenance Orders
Maintenance Budgeting (Through FI/CO Module)
Condition Monitoring (Through measuring points/counters)
Spare Part Planning
Report Analysis
To carry out these processes, certain Masters are required to be maintained prior to carry out the Transactions and Reports.
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Sl. Process Description/remarks Gap

Process Name Mode Remarks
No. (Y/N)
1.0 Masters
All Spare Parts, Consumables used in building of machine or repair

will get a unique material code. This code will be unique for the
whole organisation and will not change at Plant level. Basic data of
the materials will be maintained at client level while the other data
will be maintained at purchase organization and plant level.
The material master for spare parts will have several views like Will be
Spare Parts, Fully Basic Data, Purchasing View, MRP, Accounting view etc. done with
1.1 Components, system N the co-
Assemblies supported The Spare Parts, which are accepted after inspection will be ordination
subjected to Quality Inspection. For such material Quality of MM
Management View will be activated and necessary master date will
be created for the automatic inspection lot creation and results
recording and usage decision for the Spare parts.
For VED analysis (V-Vital, E-Essential, D-Desirable) one field will be

used in the material master of the spares so that this analysis can
be done.
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No. (Y/N)
The spare part in SAP is maintained with the valuation category. In

the valuation category, the valuation type is maintained. These
valuation types can be damage, repair etc. Each of the valuation
type has certain value attached to it.
Will be
Fully done with
Valuation type of During the maintenance activities, spare parts are replaced with
1.2 system N the co-
Spare Parts new or repaired one. The defective spare parts are repaired also.
supported ordination
In SAP, the maintenance and cost of repair of such defective spare
of MM
parts is maintained using Refurbishment Order. Repaired part can
be stored at different storage location.
The activity is directly linked to MM as well. Hence the valuation
class and type will be in accordance and consultation with MM.
Catalogs are used to manage, uniformly define, and standardize

information (for example, cause analysis for the failure of the
Fully
machine) on a client-wide basis. The catalogs help in recording the
1.3 Catalog system N
information with ease and sorting out the activities as well.
supported
In the catalogs, each unit of information is assigned a unique
alphanumeric code and an explanatory text.
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No. (Y/N)
The different catalog types are Object Parts, Cause, Damage,

Task, Activities, etc. The task and Activities are similar with
different presentation structures. In Task Screen, for each task,
Planned Start date, Planned Finish date, Completed By and
Completion Date can be mentioned. In Activities Screen, Start
Date and End Date can be mentioned.
Code groups are used to combine and structure codes within a

Fully
catalog type. Code groups are used at client level to group codes
1.4 Code Group system N
that have the same contents or relate to one another, within a
supported
catalog type. Assigned codes to a group are called as Code Group.
Functional Functional location is an organizational unit within Logistics, which

Location structures the maintenance objects of a company according to
Fully
Create / functional, process-related or spatial criteria. A functional location
1.5 system N
Change/Display represents the place at which a maintenance task is to be
supported
Functional Location performed.
Master Data
A functional location represents an area at which an object can be
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No. (Y/N)
installed. The objects that can be installed at functional locations
are called pieces of equipment
Records can be kept of the maintenance tasks that are performed;
technical data can be collected and evaluated over long periods of
time and the costs of maintenance tasks can be monitored for the
individual areas. Analysis can be carried out on the influence of
usage conditions on the damage susceptibility of the pieces of
equipment installed.
The use of equipment master records in the Plant Maintenance

(PM) application component enables to define individual machine,
motor as a piece of equipment. Equipment for which any
Equipment Master
Fully maintenance activities are carried out, are maintained in the
Create/Change/Displa
1.6 system Equipment Master. The cost of maintenance of equipment based N
y Equipment master
supported on type of maintenance can be monitored.
Data
If the equipment is very big, then equipment and sub-equipment
can be created in SAP.
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No. (Y/N)
The Start up date field indicates the installation & commissioning

date. This indicates the date on which the equipment is
operational.
The Acquisition date indicates when the asset is purchased.

Fully
Start up &
1.6.1 system N
Acquisition Date The use of this date is for information as well as for deciding the
supported
ageing of the equipment so that the maintenance planning can be
updated e.g. during the initial installation period the preventive
maintenance requirement is lower but after years of usage, the
requirement of preventive maintenance planning frequency
increases.
The ABC Indicator in an Equipment signifies the importance of that

equipment in the manufacturing scenario. This helps in prioritising
Fully
the maintenance planner to execute the maintenance activities in
1.6.2 ABC Indicator system N
the plant.
supported
There will be four types for maintenance and one for calibration
for the ABC Indicator as the outcome of the discussion:
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No. (Y/N)
A: Very high Production Loss

B: Major Production Loss
C: Minor Production Loss
D: No production loss (Spare assembly)
Q: Quality Loss (for Calibration Instruments)
Warranties define the scope of the services that a company

performs at a technical object in the event of damage or problems.
It is a commitment of the manufacturer, vendor, or retailer to

Fully
guarantee services to a customer either free-of-charge or only
1.6.3 Warranty system N
charged in part, over a certain period of time.
supported
The warranty period of the equipment can be mentioned in the
equipment master. This gets pop up when a user wants to create
maintenance order for the equipment during the warranty period.
Fully
1.6.7 Permits system Agreement required depending on setting before an order may be N
supported released or technically completed.
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No. (Y/N)
Permits are used to ensure that special approval must be obtained
before orders are executed.
Permits can be assigned to the following objects:
Technical objects functional locations and equipment
Orders
Permits can cover the following areas:
The way the order is executed or the safety aspects

involved
Safety precautions for the employees and surroundings:
Providing ear protection for employees or acidproof
equipment, safeguarding the work area, installing a flame-
proof zone, work clearance certificate
How the execution of an order is organized
Budget guarantee, approval of plant manager
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No. (Y/N)
Budget for maintenance can be done at the maintenance cost
center level. Apart from budget, we can also give the planned Through
System
1.7 Budget expenses for maintenance. N FI/CO
supported
Module
Cost center and budget will be done in CO module.
The classification system allows you to use characteristics to

describe all types of objects, and to group similar objects in classes
to classify objects, in other words, so that you can find them
more easily later.
Classification
Fully
Creation/change of You then use the classes to help you to find objects more easily,
1.8 system N
Class and using the characteristics defined in them as search criteria. This
supported
Characteristics ensures that you can find objects with similar or identical
characteristics as quickly as possible.
Characteristic is a property that describes and differentiates

objects.
Example: length, color, weight, etc.
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No. (Y/N)
Class is an assembly of characteristics that can be attributed to a
product (or to several similar products). It can also be defined as a
grouping of similar products according to common characteristics
Example Pump class, Boiler class etc.
A rule for the sequence of planned maintenance and predefined

tasks.
Maintenance
Fully
Strategy
1.9 system A maintenance strategy contains the maintenance packages that N
Creation/Change of
supported define the cycle in which the tasks must be performed, for
Maintenance strategy
example, every two months, every 5,000 km, every 500 operating
hours. Maintenance strategies are obligatory in strategy plans.
Work Center Fully Work center describes the logical station where work is being
1.10 Creation/Change of system carried out. N
Work centers supported The plant will have one or more work centers.
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No. (Y/N)
Equipment Task List is the description of the procedure for

maintaining a maintenance object called Equipment. Maintenance
task lists is the generic term used for all task lists specifically to
Equipment task list. A maintenance task list contains operation.
Maintenance Task
The maintenance task list uses a strategy for planning of
List
Equipment Maintenance for the defined period say weekly,
Creation/Change of
monthly, quarterly etc. Operation can be processed internally or
Task-lists Fully
externally. The activities defined for an external operation are
1.11 system N
requested using orders.
(For Preventive supported
Maintenance, Shut
There are two types of Equipment Task List: Equipment Task List
down Activities, and
and General Task List. Equipment task List can be attached only to
Calibration)
one Equipment Task List. But General Maintenance Task List can
be attached to several Equipments. The General Equipment task
List is used for the Preventive Maintenance where the similar
equipments undergo Preventive Maintenance Scheduling.
Strategy Plan
Fully
Creation/Change of Strategy Plan defines the description of maintenance and tasks to
1.12 system N
Maintenance Plans be performed on maintenance objects. The dates and scope of the
supported
tasks are also defined here.
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No. (Y/N)
(For Preventive
Maintenance, Shut A maintenance plan is structured based on a maintenance
down Activities, strategy. A maintenance plan contains one or more maintenance
Calibration items, in which the maintenance objects to be maintained and the
corresponding task list has been defined. The maintenance tasks
to be performed on a due date are determined by the
maintenance task list assigned to the maintenance item. The
necessary maintenance orders are automatically generated for a
due maintenance date.
Based on the maintenance plan, we can schedule the

Scheduling for the Fully Preventive/Shut down/Calibration Plan for the whole of the
1.13 Equipment system scheduling period or we can use deadline monitoring to carry out N
supported the scheduling of the Preventive Maintenance Orders for fixed
period of say one month etc.
Equipment /
Material BOM (Bill Fully Any equipment is made of some assemblies and the assemblies
1.14 of Material) system are further made of spare parts and small components down the N
Creation/ Change of supported level.
BOM
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No. (Y/N)
The equipment BOM gives ready list available to record the
critical spare part list for any equipment. The same list can be
referred to create preventive maintenance planning.
In the equipment BOM, create the spare part list, quantity and
stock type (non-stock or stock item). This master helps in
identifying for which material Purchase Requisition will be made or
Reservation is created.
For assemblies also we need to create BOM (Material BOM).
A physical or logical place at which a condition is described.

Example can be Temperature inside a reactor, Speed of revolution
of a wind wheel, the status is described using measurement
Measuring Points
Fully readings, the operating duration of Diesel Generator etc.
and Counters
1.15 system N
Creation/ Change of
supported Measuring points are stored in the SAP System as master data for
Measuring Points
the Equipment. It can work as a counter to record the duration,
based on manufacturer guidelines, the Preventive Maintenance
Orders can be generated for the same.
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No. (Y/N)
Counter are defined as Measuring Point in SAP and Counter
readings are taken at counters at particular intervals and in
particular measurement units. For example, counter readings for
kilometers driven, operating hours or electricity used.
A key that determines the origin, content, and other features of

maintenance activities. The Maintenance notification includes
malfunction, activity reports and maintenance requests. It gives
Fully the equipment location data, malfunction start and end date/time,
2.0 Notification system duration of total breakdown, priority etc. N
supported
Maintenance notifications document maintenance tasks
completely, and make them available for analysis in the long term.
You can use them for preliminary planning and execution of tasks.
Order is a task to perform within a company. The order specifies

Fully
the type of task to perform, how and when it will be performed. It
3.0 Maintenance Order system N
also defines the rules for the settlement of the costs.
supported
Maintenance order to be used whenever any cost is involved for
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No. (Y/N)
maintenance activity, i.e., external services required or
components required for maintenance. Orders will be used in Plant
Maintenance Module for classifying different type of activities for
an equipment, functional location etc.
For the new purchased assets, Internal Order can be used for cost
involved in purchasing, erecting and commissioning activities.
These orders will be created in CO module.
External Services are the external support required from the expert
for the maintenance of equipments. This process can be required
Fully for Preventive, Breakdown or any other type of maintenance.
4.0 External Services system Hence this becomes a common process required for any N
supported maintenance activities.
The different steps of confirming an external service are given
below.
Creation of Fully
In general, Plant Maintenance Internal control Key (PM01) is used.
4.1 operation using system N PM/MM
PM03 control key supported
Wherever the external services are required, in the relevant
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No. (Y/N)
operation of that order, the PM03 (Plant Maintenance External
Services) control key is used. Using this key, the system requires
the Service No. / Description, Quantity and price of the service.
Based on the MM requirement for Purchase Requisition, certain
fields are required to enter.
On saving the order, the system creates the Purchase Requisition

number for the external services. This PR number is used to create
the Service Purchase Order by MM.
For confirmation of external services, Service Entry Sheet is used.

The service entry sheet is created with reference to the Service
PO.
Fully
Confirming the
4.2 system N
External Services In the service entry sheet, the number or percentage of services is
supported
confirmed. Accordingly the data is updated in Controlling and
Financial Accounting for releasing the payment for the external
services.
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No. (Y/N)
There are many instances when based on the noise factor, heat
dissipation etc. the prediction of machine failure can be made. In
Predictive
such cases, maintenance activities are carried using Predictive
Maintenance/ Fully
Maintenance. The decisive factor in this case is that there is no
5.0 Routine system N
malfunction.
Maintenance/Gene supported
ral Maintenance
Here Predictive Maintenance Notification is created to record the
damage cause, activities undertaken.
User / maintenance in-charge creates a Predictive Maintenance

Notification (Maintenance Request) based on the abnormal
behaviour indicated in the machine during the operation in the
Notification by the
Fully machine. Notification type M1 is to be used. In this the status of
user / maintenance
5.1 system the machine before and after malfunction, date and time of N
in-charge of the
supported malfunction and priority etc. are defined.
machine (M1)
The location and other necessary data get copied into the
notification from the equipment master.
Create maintenance Fully

5.2 order from system After receipt of the notification, the maintenance department N
Notification supported creates the Maintenance Order (Order Type - PM01) using the
screen of notification in change mode. Then describes the
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No. (Y/N)
operations, requirement of spare parts for the maintenance
activities in the order and Release for and issue of spares and
confirming the activities.
If any operation requires External Services, then Steps as

mentioned in 5.1 and 5.2 will also be used.
During maintenance of the machine (outside SAP), spares required

will be mentioned in the order. Saving the order will create a
reservation for the stock-able spares. Then Order to be released
Fully and against the Order Number or reservation number, material will
5.3 Order Execution system be issued by the store. For non-stock spares, Purchase Requisition N
supported is created from the order. Based on the release strategy it can be
released for procurement and Purchase Order will be created by
the MM. Upon receiving the material, it will be issued against the
maintenance order.
Fully
Order Completion
5.4 system After completion of maintenance activities, the order needs to be N
Confirmation
supported confirmed. Order confirmation can be done partially or final. It is
CONFIDENTIAL


No. (Y/N)
confirmed. Order confirmation can be done partially or final. It is
used to record how the work is progressing. For partial
confirmation, order must not yet have been completed fully.
You use the remaining functions for the completion of an order,

after the order has been completed fully and a final completion
entered.
You enter time completion confirmations for operations and sub-

operations for maintenance and service orders to document the
status of the processing for these operations. After that all the
operations of the order needs to be confirmed. Extra stockable
issued material can be returned to stores from the order.
Fully
The Planned vs. actual costs can be viewed after all issues and
5.5 View Costs system N
service entry sheets are completed
supported
Fully
Change / Complete Notification will be closed after noting down all catalog & details of
5.6 system N
Notification maintenance required to be recorded.
supported
CONFIDENTIAL


No. (Y/N)
After confirmation for the maintenance order, the order needs to

Fully
Technically and be technically completed and settled to the appropriate cost centre
5.7 system N
Business Completion based on settlement profile.
supported
When all the costs are settled and no further activities are pending
against that order, business completion for the order is done.
The Breakdown maintenance refers to the sudden failure of the

machine to produce the desired results / output.
An employee from production would use a malfunction report to
report that:
A production system is not functioning properly.
Fully
Breakdown Performance has reduced for a production system, or that
6.0 system N
Maintenance the system is not functioning at all.
supported
A production system is producing goods of poor quality.
This is carried using a formal intimation by user department for the

maintenance of the equipment. The record of total repair time is
used to calculate Mean Time To Repair.
CONFIDENTIAL


No. (Y/N)
Like the Breakdown slip, here in SAP the user creates a breakdown
notification to intimate the Maintenance Department for the
Notification by the breakdown in the machine. In this the user defines the status of
Fully
user of the machine the machine, date and time of breakdown and priority of the
6.1 system N
(Malfunction Report breakdown.
supported
M2)
After receipt of the notification, the maintenance department

creates the Maintenance Order (Order Type - PM02) using the
Create maintenance Fully operations, requirement of spare parts for the maintenance
6.2 order from system activities in the order and Release for and issue of spares and N
Notification supported confirming the activities.

CONFIDENTIAL


No. (Y/N)

maintenance order.
After completion of maintenance activities, the order needs to be

Fully
Order Completion confirmation, order must not yet have been completed fully.
6.4 system N
Confirmation
supported You use the remaining functions for the completion of an order,
entered.
CONFIDENTIAL


No. (Y/N)
Fully
supported
Fully
6.6 system N
supported

be technically completed and settled to the appropriate cost centre
Fully
Technically and based on settlement profile.
6.7 system N
Business Completion
supported
CONFIDENTIAL


No. (Y/N)
Preventive maintenance is the scheduled / planned maintenance

based on the manufacturer recommendation or own experience.
Here a frequency called Strategy for Maintenance is maintained
Fully based on Duration or the operating hours.
Preventive
7.0 system N
Maintenance
supported The activities unlike other maintenance are much clear in advance
and are documented in the maintenance Task list. The spare parts
as well can be planned and stocked for the periodic maintenance
activities.
In Preventive Maintenance, certain master data needs to be

maintained. The task list, strategy plan, measurement counter
(optional) etc. are maintained for equipment. Measurement
Preventive
Fully Counter uses a class characteristics say operating duration. The
Maintenance order
7.1 system counter is created for the equipment. For recording the status / N
generation from
supported data of the counter, measurement document is created.
schedule.
The equipment task list contains the list of operation and sub-
operations. The spare and consumables required for the
completion of the maintenance operations can also be maintained
CONFIDENTIAL


No. (Y/N)
in the task list. Based on the release of maintenance order, the
reservation for the stock-able spares and consumables are created
in the system. For non-stock spares, the PR is created from the
maintenance order.
The equipment plans are then scheduled (periodically) using

deadline monitoring for a target period of say one month. The
scheduling creates Preventive Maintenance Orders (Order type
PM03) automatically for the period.
On the due date, the required spares can be issued from the store.
Based on the order created, a notification is also generated by the
Notification for system. The purpose to create a notification is to record the
Fully
recording activities activities done during the Preventive Maintenance. Also it can be
7.2 system N
Activity Report (M3) the ready reference for the activities left for future Maintenance.
supported
CONFIDENTIAL


No. (Y/N)

maintenance order.

Fully
Order Completion confirmation, order must not yet have been completed fully.
7.4 system N
confirmation
supported You use the remaining functions for the completion of an order,
entered.
CONFIDENTIAL


No. (Y/N)
Fully
supported
Fully
7.6 system N
supported

Fully
Technically & based on settlement profile.
7.7 system N
Business Completion
supported
CONFIDENTIAL


No. (Y/N)
Refurbishment order is the special order, which are used for the
refurbishment of repairable spares. In the refurbishment order,
contract a work centre to restore faulty repairable spares to full
Fully working order at a certain date.
Refurbishment
8.0 system N
Order
supported The repairable spares scheduled in the order are brought from a
uniform initial condition to a uniform end condition. To distinguish
the condition of damage to repair for spares different valuation
types are used.
Notification for Fully Maintenance person will create a notification to intimate the
8.1 Refurbishment (M4) system workshop Department for the refurbishment in the component N
supported
Create Refurbishment Create the Refurbishment order with order type PM04. The order
Fully
Order for the damage is created for the damaged Spare Part Material. The valuation type
8.2 system N
spare of spares is maintained in the Accounting 1 view in the material
supported
Order Type (PM04) master.
CONFIDENTIAL


No. (Y/N)
Create appropriate operations with internal maintenance,
consumables required for the Repair of the spare part. The
valuation type present and future (after repair) is mentioned in the
order. Release the order and save it.
During refurbishment of spare (outside SAP), consumables

required will be issued against the reservation created in the order.
Internal maintenance will be carried inside the plant. After that for
external repair, MM will create subcontracting order for the spare.
Fully
The receipt of the subcontracting order will result into the
8.3 Order Execution system N
valuation type change from damage to repair and cost of repair
supported
will be loaded into the spare.
For internal maintenance, the spare will be repaired using internal

spares and consumables. The cost of such repair will be settled to
the maintenance cost centre.
Fully
Order Completion
8.4 system After completion of maintenance activities for the spare, all the N
Confirmation
supported operations of the order need to be confirmed. Based on the
valuation type, the spare valuation is modified from the damage to
CONFIDENTIAL


No. (Y/N)
valuation type, the spare valuation is modified from the damage to
repair and good receipt is made for the spare.
Fully
service entry sheets are completed.
supported

Fully
8.6 system N
Business Completion
supported
Fully
A Safety activity describes a notification meant for carrying out
9.0 Safety Order system N
jobs related to safety requirements.
supported
CONFIDENTIAL


No. (Y/N)
User / maintenance in-charge creates a Notification for activities

Notification by the
Fully required for safety purpose for the equipment.
user / maintenance
9.1 system N
in-charge of the
supported The location and other necessary data get copied into the
equipment (M6)
After receipt / creation of the notification, the maintenance planner

creates the Maintenance Order (Order Type- PM06) using the
screen of notification in change mode.
The other way is to create order directly, describing the
9.2 order from system N
operations, requirement of material for the development activities
Notification supported
in the order and Release the order.

Fully
9.3 Order Execution system During maintenance of the machine (outside SAP), spares required N
supported will be mentioned in the order. Saving the order will create a
CONFIDENTIAL


No. (Y/N)
and against the Order Number or reservation number, material will
be issued by the store. For non-stock spares, Purchase Requisition
is created from the order. Based on the release strategy it can be
maintenance order.

Fully
Order Completion You use the remaining functions for the completion of an order,
9.4 system N
Confirmation after the order has been completed fully and a final completion
supported
entered.

CONFIDENTIAL


No. (Y/N)
Fully
supported
Fully
9.6 system N
supported
After confirmation for the development maintenance order, the

order needs to be technically completed and settled to the
Fully
Technically and appropriate cost centre based on settlement profile.
9.7 system N
Business Completion
supported
CONFIDENTIAL


No. (Y/N)
Improvements, Developments, Modifications or design changes are

Improvement /
necessary part of maintenance to upkeep the equipment for higher
Modification / Re- Fully
productivity period, lower breakdown repair time etc.
10.0 design / system N
Development/CAP supported
These design change / modifications costs will be separated from
EX
other costs of maintenance using a separate order type.
User / maintenance in-charge creates a Notification for required

Notification by the design change / modification activities required for the equipment
Fully
user / maintenance mentioning the purpose and results expected.
10.1 system N
in-charge of the
supported
equipment (M5) The location and other necessary data get copied into the

creates the Maintenance Order (Order Type PM05) using the
10.2 order from system N
screen of notification in change mode.
Notification supported
CONFIDENTIAL


No. (Y/N)
operations, requirement of material for the design change /
modification activities in the order and Release the order.


Fully
supported
maintenance order.
Fully After completion of maintenance activities, the order needs to be

Order Completion
10.4 system confirmed. Order confirmation can be done partially or final. It is N
Confirmation
supported used to record how the work is progressing. For partial
CONFIDENTIAL


No. (Y/N)
entered.

Fully
supported
Fully
10.6 system N
supported
Fully
Technically and
10.7 system After confirmation for the development maintenance order, the N
Business Completion
supported order needs to be technically completed and settled to the
appropriate cost object based on settlement profile. The cost of
CONFIDENTIAL


No. (Y/N)
appropriate cost object based on settlement profile. The cost of
these types of orders can be settled to the fixed asset.
During plant shut down, maintenance department get good

opportunity to do some maintenance work to upkeep the
equipment for higher productivity period, lower breakdown repair
time etc. Shutdown activities can be planned and scheduled in
Fully
Shut Down advance.
11.0 system N
Maintenance
supported
These shut down maintenance cost will be separated from other
costs of maintenance using a separate order type.
Shut Down Activities for the equipment are planned therefore it
can be taken similar to preventive maintenance.
Fully
Create maintenance As per the schedule, system will generate shutdown orders (PM07)
11.1 system N
order for the equipments.
supported
CONFIDENTIAL


No. (Y/N)
operations, requirement of material for the design change /
modification activities in the order and Release the order.

System will creates a Notification for shutdown activities required

Fully for the equipment mentioning the purpose and results expected.
Shut Down
11.2 system N
Notification (M7)
supported The location and other necessary data get copied into the

Fully
supported
CONFIDENTIAL


No. (Y/N)
maintenance order.


Fully
Order Completion after the order has been completed fully and a final completion
11.4 system N
Confirmation entered.
supported
CONFIDENTIAL


No. (Y/N)
Fully
supported
Fully
11.6 system N
supported
After confirmation for the development maintenance order, the

order needs to be technically completed and settled to the
Fully
Technically and appropriate cost centre based on settlement profile.
11.7 system N
Business Completion
supported
The Workshop orders will be used for repair of spares/parts in the

Fully
Central Workshop.
12.0 Workshop Orders system N
supported
The expenditure of such maintenance is recorded through
Workshop Notification only.
CONFIDENTIAL


No. (Y/N)
User / maintenance in-charge creates a Notification for required

Notification by the
general maintenance activities required for the functional location
user / maintenance Fully
mentioning the purpose.
12.1 in-charge for the system N
functional location supported
(M9)
notification from the functional location master.

creates the Maintenance Order using the screen of notification in
change mode.
12.2 order from system The other way is to create order directly, describing the N
Notification (PM09) supported operations, requirement of material for the general maintenance
activities in the order and Release the order.

CONFIDENTIAL


No. (Y/N)

maintenance order.

Fully confirmed. Order confirmation can be done partially or final. It is
Order Completion
12.4 system used to record how the work is progressing. For partial N
Confirmation
supported confirmation, order must not yet have been completed fully.
CONFIDENTIAL


No. (Y/N)
entered.

Fully
supported
Fully
Change / Complete
12.6 system Notification will be closed after noting down all catalog & details of N
Notification
supported maintenance required to be recorded.
After confirmation for the general maintenance order, the order
Fully needs to be technically completed and settled to the appropriate
Technically and
12.7 system cost centre based on settlement profile. N
Business Completion
supported
CONFIDENTIAL


No. (Y/N)
The Annual Maintenance Orders are special type of external

services wherein contract for maintenance for equipment or
functional location is given to external agency.
Here the total responsibility to do preventive and breakdown

Annual Fully
maintenance shifts from the Plant Maintenance to External Body.
13.0 Maintenance system N
Such type of maintenance and confirmation to the services for
Orders supported
payment is done using the Service Purchase Order and Service
entry sheet.
To track the cost of maintenance for any equipment, PM10 Annual

Maintenance Contract will be used.
Create Fully Create a maintenance order for the equipment or a functional

13.1 Maintenance Order system location using order type PM10. N
(Type PM10) supported
In the operation screen, mention the control key as PM03 as
CONFIDENTIAL


No. (Y/N)
required in External Services. Using this key, the system requires
the Service No. / Description, Quantity and price of the service.
Based on the MM requirement for Purchase Requisition, certain
fields are required to enter. On saving the order, the system
creates the PR number for the external services. This PR number is
used to create the Service PO by MM.
For confirmation of external services, Service Entry Sheet is used.

The service entry sheet is created with reference to the Service
PO. In the service entry sheet, the number or percentage of
services is confirmed. Accordingly the data is updated in
Fully
Confirming the Controlling and Financial Accounting for releasing the payment for
13.2 system N
External Services the external services.
supported
In AMC services, the payment release (service entry sheet
confirmation) can be carried in parts say quarterly release for
payment.
13.3 Fully
Order Completion
system Only after completion of the AMC services (exhausting the whole N
Confirmation
supported service order for AMC), the operation in the order is final
confirmed and case the Final Confirmation, No remaining work,
CONFIDENTIAL


No. (Y/N)
confirmed and case the Final Confirmation, No remaining work,
clear open reservation ticks are made.
In other case, order can be confirmed partially. In this case the

Final Confirmation, No remaining work, clear open reservation tick
is not made.
The confirmation text can be written for comments.
After final confirmation for the AMC order, the order needs to be
technically completed and settled to the appropriate cost centre
Fully
13.4 system N
Business Completion
supported
Fully Special order that tests whether a specified piece of test

14.0 Calibration Orders system equipment fulfills the performance criteria defined. N
supported For calibration, we need to define Characteristics and assigned it
to the task list.
CONFIDENTIAL


No. (Y/N)
When the order is released, the system generates an inspection

lot. The inspection lot appears in the work list for results recording
in the Quality Management (QM) application component.
You create a creation order if you want to check the accuracy of a

piece of test equipment or a technical object.
If you want to do this regularly (= planned), you use a

maintenance plan, which regularly generates calibration
orders.
If you do not want to do this regularly (= spontaneously), you
create a calibration order directly.
Prerequisite-
The equipment, for which you want to create a calibration order,
must be created as a piece of test equipment.
An inspection type for Plant Maintenance must be defined. This

inspection type must be created for origin 14 (Plant Maintenance).
CONFIDENTIAL


No. (Y/N)
The maintenance planner creates the Maintenance Order (Order

Fully
Create Calibration Type PM08) manually or the system will generate it if its
14.1 system N
order planned.
supported
Fully
After creating the order, for execution purpose the planner need to
14.2 Order Release system N
release the order.
supported
Fully When the order is released, the system generates an inspection

Inspection Lot
14.3 system lot. The inspection lot appears in the work list for the results N
Generation
supported recording in Quality Management.
The results recording and usage decision for the test equipment
Fully are made using the functions in Quality Management. Will be
14.4 Results Recording system N done by
supported As soon as you have made the usage decision, the system QM
automatically executes follow-up actions, for example, status
change of the test equipment ("Ready for use" -> "Not ready for
CONFIDENTIAL


No. (Y/N)
use") or updating measurement readings.
Fully After that all the operations of the order needs to be confirmed.
Order Completion
14.5 system Extra stock-able issued material can be returned back from the N
Confirmation
supported order.
After confirmation for the general maintenance order, the order

needs to be technically completed and settled to the appropriate
Fully
Technically and cost centre based on settlement profile.
14.6 system N
Business Completion
supported
In SAP, all the spares of equipment are formally structured as

Fully
Spare Parts maintenance bill of material (BOM). The list contains the
15.0 system N
Planning component number along with their quantity and unit of measure.
supported
The components mentioned in BOM can be stock-able or non
CONFIDENTIAL


No. (Y/N)
stock-able. This becomes easy reference for the Spare Part
Planning for carrying out maintenance activities.
During the creation of maintenance order, spares and

consumables required for the maintenance of the equipment are
mentioned in the order.
For all stock-able materials, reservation is created in the system

Fully automatically. The reservation is available for the Store so that
15.1 Order Release system material can be issued against the reservation. N
supported
For all non stock-able materials, Purchase Requisition (PR) is
created automatically following the release of the order and saving
the order. After release of the PR based on release strategy, the
material department creates the Purchase Order with reference to
the PR and arranges the material for maintenance.
There are many instances that the maintenance is left with the
Fully
Order stock-able spares unconsumed. Such spares can be returned to
15.2 system N
Confirmation store for future maintenance activities at the time of order
supported
completion confirmation.
CONFIDENTIAL


No. (Y/N)
In SAP, condition monitoring can be done through measuring

points. For that we need to create and assign measuring points
and then on regular basis we need to take readings at those
Condition System
16.0 measuring points and post measuring document. N
Monitoring supported
Once we capture all the reading then we can get the graph or take
corrective action based on that.
A physical or logical place at which a condition is described.

Example can be Temperature inside a reactor, Speed of revolution
of a wind wheel, the status is described using measurement
readings, the operating duration of Diesel Generator etc.
Create Measuring
System
16.1 Points for Measuring points are stored in the SAP System as master data for N
supported
equipment the Equipment. It can work as a counter to record the duration,
based on manufacturer guidelines, the Preventive Maintenance
Orders can be generated for the same.
Counter are defined as Measuring Point in SAP and Counter

readings are taken at counters at particular intervals and in
CONFIDENTIAL


No. (Y/N)
particular measurement units. For example, counter readings for
kilometers driven, operating hours or electricity used.
Create Measuring System The measurement document is the result of a measurement or

16.2 N
Document supported counter reading being entered in the system.
Take necessary
If the reading is not in the range of accepted value then you need
action System
16.3 to take a corrective action by creating maintenance request and do N
(Maintenance supported
the maintenance work.
Request)
CONFIDENTIAL

Special Points:
1. All maintenance order costs will be settled at the cost centre level but development orders can be settled at fixed asset.
2. With MM discussion, there will have two valuation types for a spare: With value and zero value. The cost of damage spare will be taken as
zero and cost of repair spare will be booked at the maintenance cost center. The maintenance cost of spare will be settled to the
maintenance order and will not be loaded to the spare.
3. Name of person creating the maintenance notification and notification attended will be given in the two separate fields in (notification
reported By and Technically Inspected By) notification.
4. Permits will be used in SAP but at the time of release system will only give warning message if permit is not issued but error at the time of
order completion.
5. Separate storage locations for maintenance (in workshop) can be defined for transferring low value components from stores.
6. Authorization for order creation & execution will be at shift engineer level but the order release will be at planning head (HOD) level.
7. For insurance claim, we can create a general notification type for capturing the information (if required).
CONFIDENTIAL

Integration with Other Modules:
MM
1. Valuation Classes will be defined for Electrical Spares/Mechanical Spares, Instrumentation Spares, Civil components and General Items (e.g.
Engg. Consumables). Also valuation classes would be defined for Electrical Service, Mechanical Service, Civil Repairs and Instrumentation
service.
2. MRP views to be maintained for critical spares (Insurance) and consumables.
3. Service Master to be maintained
FI/CO
1. Product-wise / department-wise cost center will be created, e.g., Hydrate Mechanical, Hydrate Electrical, Hydrate Instrumentation, Hydrate
Civil; Alumina Mechanical, Alumina Electrical, Alumina Instrumentation, Alumina Civil; Utilities; Non-Plant etc.
2. G/L accounts will be created for all the different valuation classes mentioned above.
3. Cost-center-wise Budget allocation will be done.
CONFIDENTIAL

List of Reports for Analysis
1. Detailed Breakdown Analysis-Equipment-wise/object part wise/Problem-wise/cause wise

2. MTTR and MTBF analysis for Equipments
3. Order type-wise cost analysis
4. Planner-group wise cost analysis
5. Equipment/Functional Location/Location/Plant wise cost Analysis
6. Report on usage of spares for Equipments
7. Report on service and Spares costs Equipment-wise
8. Planned vs. Actual cost comparisons
9. Preventive Maintenance Schedule
10. Report on Preventive Maintenance Activities
11. Equipment History
12. Report on Measuring points/Measurement Documents
13. Report on Equipments having specific characteristics
SPECIAL REQUIREMENT (ABAP)
For condition monitoring, requirement has come to us that the upload program for entering the DCS values to the SAP system (from xls) to
be developed.
A report containing data of Consumption, Unrestricted stock, QI stock, Open PR quantities and open PO quantities for critical spares needs
to be developed for the purpose of Spares Planning.
CONFIDENTIAL

Sl. Purpose Description of Report Remarks

No.
Few Transaction for Reports Transaction
1 Technical Objects Structural Display-Equipment IH03

Structural Display- Functional Location IH01
2 Maintenance Display notifications IW29
notification (Multi-Level) Notification List IW30
Display Tasks IW67
Display Notification Items IW69
Display activities IW65
32 Maintenance order Material Where-used List IW13
Display Orders IW39
Display Orders (Multi-Level) IW40
Display Operations IW49
Display Order and Operation List IW49N
Display Component List IW3L
Material Availability IWBK
4 Completion Confirmation List IW47
confirmation
5 Measuring Document Display Measurement Documents IK17
6 Maintenance Item List display IP18
CONFIDENTIAL

Sl. Purpose Description of Report Remarks

No.
Maintenance Maintenance Plan List IP16
planning Scheduling overview list form IP24
MaintSchedule Date Monitoring IP30
Scheduling overview IP19,IP24
7 Evaluation of PMIS: Object Class Analysis MCI1
information system PMIS: Manufacturer Analysis MCI2
PMIS: Location Analysis MCI3
PMIS: Planner Group Analysis MCI4
PMIS: Object Damage Analysis MCI5
PMIS: Obj.Statistic.Analysis MCI6
PMIS: Breakdown Analysis MCI7
PMIS: Cost Evaluation MCI8
MTTR/MTBR Equipment MCJB
MTTR/MTBR Functional Location MCJC
CONFIDENTIAL

SECTION IV
ANNEXURE PROCESS FLOW CHARTS
CONFIDENTIAL

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Page 99 of 99
Version No - 1.3
PROCESS FOR HANDLING REFURBISHMENT ACTIVITIES

Spare identified for refurbishment
Plant Maintenance
No No
Carry out
Is material or External Is the spare working
Refurbishment
Business Process Blueprint
Service required to carry

activity( Outside satisfactorily?
out the job?
SAP
Yes Yes
Create Refurbishment
Order( Work Order
CONFIDENTIAL
Allocate components
services to Order Close the job
Issue Components
Purchase Order Keep the spare in stock
for future use
Carry out
Refurbishment
Activity Outside
SAP

No
Is the spare rectified
?
Yes
Create Service Entry sheet
and accept
Technically complete the
order
Vedanta Alumina Limited
SAP ECC 5.0 IMPLEMENTATION
Settle the order

CONFIDENTIAL

CONFIDENTIAL

SAP Plant Maintenance Business Blueprint

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Vedanta Alumina Limited Plant Maintenance Page 1 of 1

SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

SAP R/3 IMPLEMENTATION

Prepared by Checked by Reviewed By Signature Approved By Signature Date

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

SCOPE OF BPBP DOCUMENT 6

PLANT MAINTENANCE IN SAP - OBJECTIVE 7

SCOPE OF PLANT MAINTENANCE MODULE IN VAL 8

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

OBJECTIVE OF BUSINESS BLUEPRINT PHASE

4. Business Process Flows mapped in SAP as per the scope defined.

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

5. Closure of Mapping Phase and start of Piloting Phase of implementation

A pictorial presentation of complete SAP implementation is depicted in the following page:

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

SCOPE OF BPBP DOCUMENT

a) Business Requirements of VAL that need to be translated into SAP.

SECTION I : Scope of SAP Plant Maintenance module for the project

SECTION II : Organization structure

SECTION IV: Appendix-Process Flow Diagrams.

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

Plant Maintenance in SAP - Objective

To have Reliable Equipments with low MTTR and high MTBF

To eliminate repetitive breakdowns and thereby reduce wastage of valuable resources

These objectives will be obtained by

By having up to date cost figures (Plant-wise/Location-wise/Equipment-wise) for better maintenance decision-making

By analysing usage data on components and services related to maintenance.

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

Scope of Plant Maintenance Module in VAL

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

PARTICULARS ALUMINA POWER

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

PARTICULARS ALUMINA POWER

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

VAL Alumina 1000

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

2000 VAL Power Maintenance Plant

3000 VAL Smelter Maintenance Plant

4000 VAL JV Maintenance Plant

2000 VAL Power Maintenance Planning Plant

4000 VAL JV Maintenance Planning Plant

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3

Proposed locations for Vedanta Alumina Limited are as follows:

For Alumina Plant (1000)

RED Red Area

NPA Non Plant area

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SAP ECC 5.0 IMPLEMENTATION Business Process Blueprint Version No - 1.3