SAP Plant Maintenance

Overview
Author: Alhadi A. Nibel
SAP PM Associate Consultant
 Course List
Plant Maintenance in the R/3 System

Plant Maintenance: An overview

Organizational Structure

Master Data in SAP PM

Maintenance Processing

Business Process of Plant Maintenance

SAP Transactions
 Plant
Maintenance in
the R/3 System
 Plant Maintenance in the r/3 System

• Plant Maintenance (PM) is a high-performance application component

integrated in the logistics chain of the R/3 System that supports you when
carrying out all maintenance tasks

• The Plant Maintenance component supplements resource planning for

the maintenance of your production systems, vehicles, buildings and so on,
across all branches of industry.
 PM application component has already been
successfully implemented
• Automotive industry • Petrochemical industry
• Chemical industry • Pharmaceutical industry
• Commerce/service industries • Precision engineering
• Energy suppliers
• Primary industries
• Electronics industry
• Public service industry
• Food industry
• Publishing industry
• Mechanical engineering
• Metal-working industry
• Software and computing

• Mining industry
• Steel industry

• Paper industry • Transportation industry

 Plant
Maintenance:
An overview
 What is SAP Plant Maintenance
• Plant Maintenance is a function or an essential support system in an
industrial process. This system helps and keep all the machinery and
infrastructure into prime condition or ideal in terms of quality and
operational.

SAP Plant Maintenance comprises the following activities:

• Inspection
Determining the actual condition of a technical system
• Preventive Maintenance
Maintaining the ideal condition of a technical system
• Repair
Restoring the ideal condition of a technical system
Organizational
Structure
 Organizational Structure

• Maintenance Planning Plant: Plant in which maintenance tasks are planned

and prepared. Example: Maintenance planner group, maintenance work
centers
• Maintenance Plant: Plant in which the technical objects of a company are
installed. Example: Building, production area
Master Data
in SAP PM
Master Data in SAP PM
Functional
Location

Work
Equipment
Centres

SAP PM:
Master
Data
Class/ Bills of
Characteristics material

Measuring
Point/
Counters
Maintenance Work Center
 Structured Clarification Functional Location

Functional locations enable you to structure maintenance

objects according to the following criteria:

• Functional (for example, ”pump station,” ”power unit”)

• Process-oriented (for example, ”polymerization,” ”condensation”)

• Spatial (for example, ”hall,” ”location”)

 Equipment Hierarchy

• A piece of equipment is an individual physical object maintained as an autonomous unit.

Pieces of equipment usually represent single objects such as pumps, motors, vehicles, for
which maintenance tasks should be performed and recorded.
• Equipment can be installed at functional locations. A piece of equipment can be linked with
a material, if there is inventory management, in the sense of Materials Management, for
the object.
 Structure of a Bill of Material

An individual bill of material can be defined for each maintenance object.

The bill of material contains the following information:
• Structure of the unit (using assemblies)
• Spare parts for its maintenance (for example, stock items, external material, documents, and texts)
Maintenance
Processing
Workflow-Supported Maintenance Processing for
Unplanned Maintenance Tasks
 Planning Maintenance Tasks
• Direct creation of a maintenance order
Order

• Creation of a maintenance notification with immediate order

Notification Order

• Creation of a maintenance order based on a notification

Notification Order

• Combination of maintenance notification to make a order

Notification
Notification Order
Notification
What is different between Notification and Work Order
• Maintenance Notifications
are Reporting objects to
record:
Maintenance requirement
Cause, Object Impacted, Tasks
due & Activities Performed
• Types: Maintenance Request,
Malfunction (Breakdown)
Report, Activity Report,
Service Notifications
• Maintenance Notifications
generally do not record Costs
• Maintenance Orders are a complete
record of:
Operations performed
Components used (Stock/Non stock)
External Services
Time, plan costs and actual costs
posted
Settlements executed
• Types: Breakdown Orders,
Corrective Orders, Predictive Orders,
Refurbishment Orders, Preventive
Orders
 Business
Process of
Plant
Maintenance
Business Process of Plant Maintenance

Breakdown Corrective Preventive Refurbishment

Maintenance Maintenance Maintenance of Spare Parts
Breakdown Maintenance Processing
Malfunction Reports Malfunction Order

Technical object Date Maintenance

Notification
Description Malfunction planner

Order release Capacity leveling

Scheduling
Printout Availability check

Technician/
Execution Planned/unplanned mat. withdrawal Storeperson

Time conf. Order settlement Maintenance

Completion
Tech. completion Technical confirmation supervisor

History
Material usage, orders, notifications, PMIS, usage list
 Corrective Maintenance Processing
Internal External Service Material

Technical object Date Maintenance

Notification
Description Malfunction planner

Work to be performed Material

Planning
Internal/external resources Tools

Order release Capacity leveling

Scheduling
Printout Availability check

Technician/
Execution Planned/unplanned mat. withdrawal Storeperson

Time conf. Order settlement Maintenance

Completion
Tech. completion Technical confirmation supervisor
Stock Material Process Flow (Reservation)
Create
Notification
(IW21)
Order Release
(IW32)
Order Planning,
Create Order refer Assign operation,
from Notification CTRL Key PM01,
(IW22) Input Stock Material Goods Issue
(IW32) Material
(MIGO)

Order
Order Order Technical Confirmation for
Order Closure
Settlement Completion Actual Work
(CO99)
(KO88) (IW32) (IW41)
Procurement Non-Stock Material Process Flow
Order Planning, Assign
Create Order refer from
Create Notification operation, CTRL Key PM01, Order Release
Notification
(IW21) Non-Stock Material (IW32)
(IW22)
(IW32)

Release Purchase Create PO refer from Goods Receipt from

Release PO
Requisition Purchase Requisition PO
(ME29N)
(ME54N) (ME21N) (MIGO)

Order Technical
Usage Decision/Quality Order Confirmation for Completion Settlement a
Inspection Actual Work maintenance order
(IW32)
(QA32) (IW41) (KO88)
Sys. Status - TECO

Order Closure
(co99)
 SAP
Transactions
Func. Loc, equipment, and BOM Structure List
Notification Transaction
Maintenance Order Transaction
Report List of Order
 Thank you
• Contact information:
Phone: (+62) 812-9790-0097
E-mail: alhadiakbar.official@gmail.com

Krakatau Consulting – PT Krakatau Information Technology

SAP Services & EBM Partner