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Plant Maintenance
Disclaimer
The information contained in this document is to be treated as confidential. No part of this document, wholly or in part
may be distributed in print or as a soft copy as it may contain information which could be the sole proprietary
knowledge of AAHG.
Maintenance Engi-
Mr. Nirav Desai
neer - API
Maintenance Engi-
Mr. Pradeep
neer - AGT
Maintenance Engi-
Mr. Mohammad
neer - EGC
AAHG Group
Operations Manager
Mr. Husam
– EESF
2 Acronyms....................................................................................................................................................... 7
4 Introduction................................................................................................................................................... 9
4.2 High level overview of the SAP Plant Maintenance Module ...................................................... 10
Organization Structure ............................................................................................................................... 11
4.2.1.1 Maintenance Plant ............................................................................................................................. 11
4.2.1.2 Planning Plant .................................................................................................................................... 12
4.2.1.3 Planner Group .................................................................................................................................... 13
Master Data ................................................................................................................................................ 13
4.2.2.1 Functional Location ............................................................................................................................ 13
4.2.2.2 Equipment.......................................................................................................................................... 15
4.2.2.3 Bill of Material.................................................................................................................................... 16
4.2.2.4 Measuring Point and Counters .......................................................................................................... 18
4.2.2.5 Task List .............................................................................................................................................. 19
4.2.2.6 Work Center ....................................................................................................................................... 21
Maintenance Process.................................................................................................................................. 21
Preventive Maintenance............................................................................................................................. 25
Reports ....................................................................................................................................................... 35
Conversions ................................................................................................................................................ 36
Functional Gaps / Enhancements / Approaches to Functional Deficit ................................................... 36
Workflows .............................................................................................................................................. 36
8 Gaps .............................................................................................................................................................49
9 Enhancements ..............................................................................................................................................49
1 Document Control
Ver-
Date Author Change Log Approved By
sion
4 April Senthil Kumar First version of Blueprint
1.0
2016 Gandhi
2 Acronyms
Acronym
Process
Reference
Process
Business
activity/
Event
Document
Exception path
Normal path
Diagram
Connecti
on
Process
decision
Manual
activity
4 Introduction
This document summarizes the findings of the Computer Sciences Corporation (hereinafter re-
ferred to as CSC) consulting team, which conducted requirement analysis of Al Ahli Holding
Group (hereinafter referred to as AAHG Group) for the SAP ECC system. The information was
gathered through workshops and discussions conducted at the AAHG Project Office with the
managers, key users, as well as reviews of business processes and business procedures fur-
nished by AAHG team after due consultations.
The immediate purpose of the analysis is to prepare to move forward rapidly with the imple-
mentation of AAHG’s SAP ECC system. At the conclusion of the blueprint, CSC Consultants will
determine the SAP functionality required to run the AAHG Group business.
The Blueprint and its associated appendices present a summarized perspective of all functional
business processes that will be implemented. As such, the Blueprint document will serve from
this point forward the dual role of both official project scope as well as system acceptance cri-
teria.
The Blueprint reiterates the SAP ECC organizational structures that have been identified and
will serve as the basis for the initial configuration activities. The CSC team believes that SAP
ECC can accurately model AAHG Group organizational requirements.
The information gathered and documented in the Blueprint is sufficient for the team to go for-
ward into the Realization phase. However, it is critical that both the CSC and AAHG Group
teams agree on the scope of the project as presented in this document. Acceptance by both
teams is required to move the project into the next phase.
This section gives an overview of the solution that will be provided for the Plant Maintenance.
A number of integrated processes have been identified that cover the way Plant Maintenance
will be carried out in AAHG group once the new system is implemented.
The SAP solution will have the Enterprise Areas of Finance, Controlling, Materials Man-
agement, Sales and Distribution, Production Planning & Control, Quality, Project sys-
tems and Human Capital Management. This document outlines and then details the sec-
tions from the process group which relates to AAHG Group Plant Maintenance Area.
The Plant Maintenance module can be divided into the following key Process Groups:
Master data
Maintenance Process
Preventive Maintenance Process
Al Ahli Holding Group is a multi-diversified international conglomerate with over four decades
of successfully dealing with business activities ranging from real estate to turnkey construc-
tion, engineering and infrastructure, retail and trading, technology and logistics, lifestyle and
fitness, entertainment, hospitality and innovative developments.
With great passion and a very active portfolio in the entertainment industry, AAHG operates
innovative and ground-breaking projects in the UAE.
Owns Dubai Outlet Mall, which is the first outlet mall concept in the Middle East.
Constructed major landmarks in the Eastern region of UAE.
Holds the exclusive largest franchise rights to US-based Gold’s Gym International in the
Middle East and Africa.
Owns Al Ahli Plastics, one of Middle East’s largest plastic manufacturing companies.
Holds licenses to publish Marvel, Warner Bros., DC Comics and Sanrio comics and activ-
ity inks.
Owns Comicave, the world’s largest comic and superhero collectibles destination store
at Dubai Outlet Mall.
Launched Singapore-based companies with Comicave Studios, manufacturer of high-
end collectibles and toys.
Owns Universal Events to host and organize comic and pop-culture based events and
conventions.
Recently acquired Audience, one of the world’s largest publishers of multi-channel so-
cial and digital content to create new direct-to-consumer media services.
Launched 117 Live, an events company dedicated to hosting international live events
and offering events-based ancillary services.
The company announced to build a Fox-branded theme park and resort in Dubai and has stra-
tegic alliances with Fox Studios, Marvel-Disney, Sony Pictures Warner Bros and other leading
Hollywood studios across its multi-entertainment based platforms.
With around 9,000 employees, AAHG is headquartered in the UAE, with representative offices
across 20 countries globally.
Plant Maintenance Module of SAP communicates with other modules in the SAP System to en-
sure a constant flow of information relates to Machineries and Assets. For example, it works
side by side with the following modules like Financial Accounting (FI), Controlling (CO), Materi-
als Management (MM), Project Systems (PS) and Sales & distribution (SD)
f. Task list
g. Catalogs
2. Business Process
a. Breakdown Maintenance
b. Preventive Maintenance
c. Refurbishment Process
d. Calibration Maintenance
e. Equipment mobilization and return process
f. Measurement document for Fuel and counters
Organization Structure
Maintenance Plant
Planning Plant
Company Maintenance
Company Country Plant description
code Plant
Al Ahli Holding Group
Al Ahli Holding Group (AAHG) UAE 1000 1000
(AAHG)
Al Ahli Plastics Indus-
Al Ahli Plastics Industries (API) UAE 1100 1100
tries (API)
Emirates General Con-
Emirates General Contracting (EGC) UAE 1200 1200
tracting (EGC)
Al Ahli Aluminium
Al Ahli Aluminium (AAA) UAE 1300 1300
(AAA)
Emirates Engineering
Emirates Engineering Services &
UAE 1400 1400 Services & Factories
Factories (EESF)
(EESF)
Gulf Spring Contacting
Gulf Spring Contacting (GSC) UAE 1500 1500
(GSC)
Al Ahli General
Al Ahli General Transport (AGT) UAE 1600 1600
Transport (AGT)
Comicave Studios - Sin-
Comicave Studios - Singapore Singapore 1700 1700
gapore
Maintenance
Planning Plant Description
Plant
1000 1000 Al Ahli Holding Group (AAHG)
1100 1100 Al Ahli Plastics Industries (API)
Master Data
Master Data is a single source of basic business data used across multiple systems, applica-
tions, and/or processes.
Below are the list of master data which are important in PM:
– Functional Location
– Equipment Master
– Measuring Point
– Bill of Material
– Catalogs
– Work center
– Task List
Functional Location is an organizational unit within Logistics that structures the maintenance
objects of a company according to functional, process-oriented or spatial criteria. A functional
location represents the place at which a maintenance task is to be performed.
Each functional location is managed independently in the system, so that you can:
Collect and evaluate data over a long period of time for the object.
Use:
A functional location represents system area at which an object can be installed. The objects
that can be installed at functional locations are called pieces of equipment in the System.
Technical data can be collected and evaluated over long periods of time for the individual areas
of the system or operational structure.
The costs of maintenance tasks can be monitored for the individual areas of your system or
operational structure.
You can perform analyses on the influence of usage conditions on the damage susceptibility of
the pieces of equipment installed.
To determine the generic structure of the location number and make the hierarchy levels with-
in the location structure visible in the location number separate structure indicators shall be
created for manufacturing and site functional locations. The Structure indicators shall be al-
phanumeric structures wherein the edit mask is represented as N (number), A (letter), & X
(both).
The coding of the functional location will be Alpha Numeric with separators and based on the
coding logic of the functional location the system will automatically derive the superior func-
tional location. However the user has the option to change the same.
4.2.2.2 Equipment
Use:
Collect and evaluate data over a long period of time for the object.
M – Technical system
The Equipment number shall be generated internally based on these equipment categories.
Equipment details shall be captured in the system using equipment master data. The data cap-
tured in the equipment master shall be as following:
General Data – Manufacturer, Manufacturer part no, serial no, year of manufacturing, Acquisi-
tion data.
Organization Data – Company code, asset, cost center, Planning Plant, Planner group, Mainte-
nance Work center.
Asset number maintained for the Asset master in the FI module can be linked to the Equip-
ment master.
Material number can be linked to the Equipment master as the construction type for indirect
linking for Bill of material purpose
Use:
Structure description:
Maintenance BOM describes the structure of a technical object or material. Using maintenance
BOMs you can specify exactly where maintenance tasks are to be performed on a technical ob-
ject.
A maintenance BOM is used in plant maintenance to assign spares for a technical object or
material.
The use of maintenance BOMs is advantageous for material planning, because it is possible to
perform material planning when creating a maintenance task list and maintenance order. BOM
can be created for individual technical object like functional location, Equipment and material
(Maintenance assembly).
Direct allocation:
Direct allocation is performed by directly linking one or more master records to a BOM, without
inserting a material master record. If all the technical objects are identical in terms of struc-
ture, the BOM items are valid for all the allocated technical objects. If individual materials or
assemblies are only valid for certain objects, a joint BOM can still be used. In this case, the
object-specific differences can be documented using variant items.
Indirect allocation:
Master records for technical objects can be indirectly allocated to a BOM if the master records
are linked to a material master record which contains its own material BOM via the field Con-
struction Type. This is the case when a company has several identical technical objects
grouped under one material number.
In the BOM, the components can be differentiated based on the following item categories for
planning purpose:
L – Stock item
This item category applies to components which are kept as stock. Any components entered
with this category in the BOM must have a valid master record in the system. When you use
this item category, stock item components are automatically reserved for the maintenance or-
der.
N – Non-stock item
This item category is used for components which are not kept in stock, if they are used in a bill
of material (BOM). Non-stock items can be entered in the BOM with or without a master rec-
ord. To enter a non-stock item without a master record, you must simply enter a descriptive
text. When you use this item category, the system automatically creates a purchase requisi-
tion for these components, when they are used for maintenance purposes. This leads to order-
specific materials procurement via the purchasing department
Measuring points describes the physical and/or logical locations at which conditions described,
(for example, the coolant temperature in a nuclear power station after the coolant has left the
pressure vessel, or the number of revolutions at a rotor shaft of a wind-driven power plant).
Measuring points are located on technical objects, in other words, on pieces of equipment or
functional locations. For example, in a storeroom for fruit, a certain room temperature has to
be created and maintained. The temperature is kept constant by a regulator, and is also
checked regularly by a measuring device. The storeroom is represented in the system as func-
tional location. The temperature measuring device is then created as measuring point for this
functional location.
Counter:
Tools that you use to represent the wear and tear of an object, consumption, or the reduction
of an object’s useful life are described as counters.
Use:
Measurement readings are taken at measuring points in particular measurement units at par-
ticular intervals. For example, the temperature in degrees Celsius of the coolant in the coolant
pipe that leaves the pressure vessel at the nuclear power station, or the number of revolutions
per minute at the rotor shaft of the wind-driven power plant.
Quantitative
Qualitative
Combination of both
Measuring points shall be following one category - M for creating internal number ranges.
Each measuring point will have a measuring position, which will be unique for every
measuring point for checking the duplications.
Measurement ranges can be assigned to individual measuring points with lower range
and upper range limit.
If the measuring point is quantitative, then a characteristic can be linked to the meas-
uring point with the unit of measurement.
In the case of counter-based maintenance, maintenance activities can be performed when the
counter of the technical object has reached a particular counter reading, for example, every
100 operating hours. Counter-based maintenance can be employed for technical systems with-
in the process.
A measurement document will be created after recording the measurement readings for a
measuring point. This measurement document number is unique and shall follow internal
numbering for generation.
Use:
Task lists help to reduce the maintenance effort when standardized work sequences change,
for example as a result of new legal regulations. You must carry out the changes at exactly
one place in the corresponding maintenance task list. All maintenance orders and maintenance
items that refer to the maintenance task list automatically receive the actual status of the
work sequences.
Can use maintenance task lists in the following areas of Plant Maintenance:
Planned maintenance
Ongoing maintenance
Maintenance task lists contain important information such as the spares and tools required for
the work steps or the time required performing the work.
General maintenance task lists are task lists that are used for general maintenance tasks. They
do not refer to a specific technical object. Using general maintenance task lists, you can define
and manage sequences of maintenance tasks centrally, and use them for work scheduling.
Within a group, you can create several individual general maintenance task lists. This clearly
identifies each general maintenance task list within the group.
Use:
General maintenance task lists help you to prepare maintenance plans and orders. Further-
more, you can use these task lists to reduce the time spent creating equipment task lists.
Task has the following elements which support in performing maintenance functions:
An operation specifies the time, work centre and other control information required for the
maintenance task.
Material components
Maintenance packages:
The maintenance cycles and packages contain the time or performance condition when
Maintenance must be performed.
Use:
Work centers are used in task list operations and maintenance orders.
Formulas and Activity type are entered in the work center, so that the costs of an operation
can be calculated. A work center is also assigned to a cost center.
A work center shall be created for a plant and is identified by a key. The work center category,
which defines in customizing the work center, determines which data can be maintained in the
work center. The work center master shall be created based on category ‘Labour’. Description
for Work Center would be position wise, as mentioned in below table.
The usage of work center shall be maintained as ‘All task list type’.
Maintenance Process
An overview of the basic process flows specific to different types of maintenance is given be-
low. These have been discussed in detail in the later paragraphs.
Notification:
When the Station Supervisor observes any malfunction in the Equipment, he can inform the
Workshop Maintenance Supervisor.
The Maintenance Supervisor can initiate the Maintenance work by creating a Notification. The
following
M2 – Malfunction Report – Can be used for reporting the malfunctions in the Equipment
or functional location
M3 – Activity Report – Can be used for jobs of which Maintenance Department wishes
to execute in Operation area
The Maintenance Supervisor can record the following details in the notification:
Coding (Predefined Damage/Cause of damage code)
Work center who are responsible to carry out the Maintenance activity
Required start and end date and time for carrying out the job
As soon as the notification is created, the system status of the notification can be displayed as
‘Outstanding Notification’.
The Maintenance person can acknowledge the notification by converting the status to ‘Put in
Process’.
If the Maintenance person wishes to carry out the activity in the later date or wishes to com-
bine with future shut down or if the spares are not available at present or if the clearance is
not available, he can convert the status of the notification to ‘Postponed’. The reason for Post-
poning can be written in the Test field.
The Maintenance Department can convert the Notification to Order. The system status of the
notification gets converted to ‘Notification in Process’ and ‘Order assigned’.
After successful completion of the activity, the Maintenance person can record the details of
the activities and findings in the Notification along with details of activity start and end date &
time.
Provision will be given for the Maintenance Department to describe the Malfunction/damage,
Object part, Cause of damage, Activities that were done to the Equipment, with the help of se-
lectable predefined texts (Catalog) to maintain the consistency in reporting and also to do the
evaluation.
Damage, Cause of damage codes shall be created and catalogued to facilitate easy data input
and detailed analysis and reporting requirements of the problems. Maintenance Supervisor af-
ter confirming the satisfactory performance of the activity can close the notification. The
Equipment history gets updated in the information system.
Maintenance Order:
Maintenance Order
Operation Done In
house. Activity cost will Requirement of stock Requirement of non Requirement of service
be captured material stock material from external agency
Creation of Creation of
Confirmation of Creation of
purchase purchase
labour hours reservation
requisition requisition
The Maintenance supervisor can initiate the Maintenance work by creating a Notification/Order.
The Maintenance person can convert the Notification into Order for attaching the required Ma-
terials and Manpower and for release the Order for the Cost center booking. The Maintenance
person can also directly create the Order.
Many Notifications can be assigned to a single Maintenance order. The history will be made
available only for the Equipment entered in the header of the Order.
The following types of Orders are proposed and can be used in the system:
PM03- Preventive Maintenance order - Can be used for Planned activities / Preventive activi-
ties
While creating Order, the Maintenance person can record the following details:
The activity description
Work center who are responsible to carry out the Maintenance activity
Planner group who plans for this Maintenance activity
Activity type
Activity planned Start date and Finish date
Related Technical objects (Functional location and Equipment)
Reservation number gets automatically generated for the Order with Materials.
A purchase requisition gets created if the material belongs to non-stock within the component
list of the Order.
The Maintenance Department can withdraw the required material from the Stores based on the
reservation created automatically from the Order.
Maintenance Department can carry out the job and upon completion of the work; user can en-
ter the time taken for each operation.
The Maintenance person can enter the completion confirmation in the system by entering the
start/end time, he can also record the Tasks carried out. They can enter the overall technical
confirmation and business completion. After the business completion, no movements can be
made possible against the Order.
Based on the Order status and the Confirmations, the progress of the Maintenance Order can
be monitored. The Equipment history gets updated in the information system.
Preventive Maintenance
Ensuring a high availability of objects in the long term is an important part of Plant Mainte-
nance. Planned maintenance is used to avoid system breakdowns or the breakdown of other
objects, which - in addition to the repair costs – often result in much higher costs subsequently
owing to production breakdown.
There are many benefits in using planned maintenance within a company. It is the generic
term for inspections, preventive maintenance and planned repairs, for which the time and
scope of the work can be planned in advance.
Manufacturer recommendations
Legislative requirements
The Maintenance Planning component is integrated with the following components and sub-
components:
Maintenance Items
Maintenance Plans
We can use maintenance planning to describe the dates and scope of plan able maintenance
and inspection activities at technical objects. Can ensure that the technical objects are main-
tained on time and thereby function optimally. The system generates maintenance call objects
during the scheduling process. The maintenance planning can be done on
Maintenance Planning:
Maintenance Plan is a means used to describe the dates and scope of the maintenance and in-
spection activities that are to be carried out at technical objects (on Equipment or on Function-
al location).
Performance based (Run hour based, kilometres etc). For such activity based mainte-
nance plan, a measuring point has to be identified in the maintenance plan, which shall
record the performance at regular intervals. If it is a counter (Like Hours or Litres, we
need to enter the average annual performance i.e. average hours/Litres run in a year)
Strategy Plan
Single cycle Plan: This type of plan can be used for the checks which are to be performed
regularly at a single frequency. For example: If we have only a few checks to be performed
every week and there are no different checks for other frequencies (say monthly), then single
cycle plan can be used.
Strategy Plan: On the other hand, if we have a few checks to be performed once in a week,
some other checks once in a month and few more checks once in three months and so on,
then we have to use Strategy Plan.
A strategy plan shall have Maintenance strategy. Maintenance strategy is the rule for sequence
of planned maintenance work. The maintenance strategy contains the maintenance packages,
which define how frequently the individual jobs are to be carried out.
For example, one maintenance strategy can have maintenance package in multiples of week
(Weekly, fortnightly etc.). Another maintenance strategy can have maintenance packages in
multiples of running hours (once in every 150 hours, once in every 300 hours, once in every
600 hours etc.).
A maintenance schedule.
Maintenance Item:
A maintenance item describes which preventive maintenance tasks should take place regularly
at a technical object or a group of technical objects. In simple words Maintenance Items link a
task list and Equipment or Functional Location.
Once the Maintenance Item is attached to a maintenance plan, on regular basis as per the
predefined frequency Maintenance orders shall get generated at regular intervals.
You can assign maintenance items to a maintenance plan in the following ways:
Can create a maintenance plan and create a maintenance item directly in the mainte-
nance plan by entering the required data in the tab Item.
The following rules apply if you assign a maintenance item to a maintenance plan:
The maintenance item you assign to a strategy plan must have the same maintenance
strategy as the maintenance plan.
The maintenance item you assign to a strategy plan must have the same maintenance
plan category as the maintenance plan.
Scheduling period:
Scheduling period is used to display a preview of the maintenance dates in the queue.
The scheduling period specifies in days, months, or years the actual length of time over which
scheduling will take place. For example, if you want a maintenance plan to be scheduled for
the entire year, so that all the calls are generated for this year, you must enter 365 days or 12
months as the scheduling period.
For example: If we give the scheduling period as 365 days, the system shall create a calendar
indicating various dates on which the different maintenance shall be due for that particular
plan. For a maintenance plan, which is activity based –based on the average run hours per
year, the system calculates the average per day running, then estimates the future dates on
which the various maintenance can fall due and then creates the calendar for the scheduling
period.
Call Horizon:
This parameter decides, the advance intimation period for a scheduled maintenance order. In
simple terms, if a given maintenance is scheduled to be due on a future date (say 1st January,
20016) it is the date on which the maintenance order should get generated on 31st December,
2017 or on 30th etc. so that the Maintenance Engineer shall be in a position to plan in ad-
vance. This ‘Call Horizon’, is to be given in terms of percentage of the smallest frequency of
the maintenance package used in the Maintenance Plan. For example, if in a maintenance plan
with ‘strategy1’ as shown in example, if ‘Call Horizon’ is given as 15%, then the minimum fre-
quency of the package used is 1 week. Then 15% of one week is approximately one day. The
scheduled maintenance order call date will be one day in advance to the scheduled start date.
Maintenance Schedule:
Regular generation of maintenance orders as per the maintenance plan has got two steps in-
volved.
Scheduling:
When a maintenance plan is scheduled, the system calculates the due dates for the mainte-
nance tasks that are to be performed for the scheduling period mentioned in the maintenance
plan.
Deadline monitoring:
By doing the deadline monitoring function, the system converts all the maintenance calls, for
which the call horizon has been reached, into maintenance orders. The system also performs a
complete rescheduling of the maintenance plan and ensures that maintenance calls are always
available for the period which you have defined as the scheduling period.
The below mentioned list of business processes are considered as part of the Implementation scope for
AAA, API, EESF, EGC, GSF and AGT
As-Is Process
When new machine is purchased, then this process will help maintenance supervisor to have
step wise approach to create relevant equipment master data in system which is required to
map life cycle of the object
To-Be process
Phase In Process
STANDARD DECISION
SAP
Event
PROCESS PROCESS
Start End START END
MANUAL MANUAL
INPUT OPERATION
Finace Dept
Create
Equipment
Master with
reference to
Asset ID
Maintenance Supervisor
Create Class
Create Task List
and
as per the Create a BOM
Characteristics
requirement
for equipments
Process Steps:
Business Situation
When new equipment is procured which needs maintenance history to be maintained in sys-
tem.
If the equipment is an asset, the asset will be created in Finance module and the Asset num-
ber will be maintained in Equipment master during this process
Scope
None Identified
Forms
None Identified
Reports
The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.
Conversions
# Requirement Description
1 AAHG-PM-CON-001 Functional location
2 AAHG-PM-CON-002 Equipment
3 AAHG-PM-CON-003 Task List
4 AAHG-PM-CON-004 Preventive Maintenance Plan
None identified
Workflows
None identified
As-Is Process
When equipment is being retired, then this process will help maintenance supervisor to have step wise ap-
proach to deactivate equipment in system. This will be done in two phases i.e. scrapped or sold. Updating
the equipment master data with relevant information
To-Be process
STANDARD DECISION
SAP
Event
PROCESS PROCESS
Start End START END
MANUAL MANUAL
INPUT OPERATION
Finance Dept
Asset
Retirement
process
Approval
Manager
Dismantle Functional Close all the pending Deactivate the Inform Finance
Identify the Location from Order of the maintenance plan of dept to scrap
equipments which Equipment Equipment Equipment the asset
are to scrapped
Process Steps:
When Equipment scrapping request is provided by field unit/production shop floor to the
Maintenance in-charge. Based on their request and approvals from the higher authorities of
maintenance equipment will be scrapped. Then update the equipment master data with
scrapped related information.
Maintenance in-charge will de-activate any maintenance plans, close any Open notifications,
maintenance order, service entry sheet etc.
Once the equipment is sold out then relevant information will be updated in the equipment
master data.
Scope
None Identified
Forms
None Identified
Reports
The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.
Conversions
None Identified
None identified
Workflows
None identified
As-Is Process
Currently there is no system for maintenance related process for creating the mainte-
nance order
Process Overview
When any machine breakdown occurred due to operational error or machine problem, Produc-
tion/Operation department will inform to the Plant maintenance department. Maintenance de-
partment will identify the identify the faults and attend the breakdown.
To-Be process
Breakdown Maintenance
STANDARD DECISION
SAP
Start End
Event
PROCESS PROCESS
START END
MANUAL MANUAL
INPUT OPERATION
Create
Stake Holder
Inform to Notification- M2
Identify requirement Login access
N maintenance type
of creating exist
dept
notification
Create a
Maintenance System creates
Create M2 Review Maintenance Component Stock
Order Y Y Y reservation
Notification Notification Order – PM01 required..? available..?
required..? number
type
Maintenance User
Close the M2 N N
Notification
Complete the
Update technical System creates
PM01 External
findings in M2 N Y Purchase
Maintenance Service Req..?
Notification requisition
Order
Technician
Execute
the work
Purchase
MM
Process Steps:
Business Situation
User will create the corrective notification against the abnormality of the technical object.
Based on the observations maintenance supervisor will convert the order to respective notifi-
cation.
Maintenance supervisor will assign the spares in the order for executing the activities of the
order
If material has to procure from externally he will create the PR for required material in the or-
der
If it is external service the service related information will be updated in the order
Scope
None Identified
Forms
Reports
The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.
Conversions
None Identified
None identified
Workflows
None identified
As-Is Process
Currently there is no system for repair those repairable spare part, and then return that
spare part back to the equipment, or to warehouse.
Process Overview
This process will help maintenance supervisor to track those High value repairable spare parts
and track the cost of total process from order creation to returns the refurbished spares to
warehouse
To-Be process
Process Steps:
1 Creation of Re- M SAP Iw81 Maintenance This order will be used for
furbishment order Supervisor usually high value- defec-
tive repairable spares to
be refurbished
2 M SAP IW32 Maintenance
Release of the Orders needs to be re-
order Supervisor leased for execution
Business Situation
Before creating the refurbishment order the same will be treated as material with valuation
details and updated in the stock.
If it is internal process after refurbishment stock with details will be updated in the refurbish-
ment valuation category
If it is external process PR will be created for material. It will be sent to outside for repair. Af-
ter refurbishment material sent back to warehouse and updated valuation category details of
stock.
Scope
None Identified
Forms
None Identified
Reports
The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.
Conversions
None Identified
None identified
Workflows
None identified
As-Is Process
Currently there is no system for preventive maintenance process for doing the mainte-
nance activities as per manuals/user recommendations.
Process Overview
When we purchase new equipment or for existing equipment’s this process will help to track
the maintenance due activities as per the manuals / user recommendations.
Based on historical quality data and technical experience, are going to change the plan Fre-
quency accordingly. Decision will be taken by maintenance HOD.
To-Be process
Preventive Maintenance
ST AN D AR D D EC ISION
SAP
Event
Start End
PR OC ESS PR OC ESS
ST AR T EN D
M AN U AL M AN U AL
IN PU T OPER AT ION
System creates a
System
Preventive
Notification – PM type
Manager
Release the
maintenance
order
Identify
Create PM03
Schedule of List all PM - technician
Is Maintenance type Component Stock System creates
Preventive Preventive Y Y Y for
Order required.? Maintenance required.? available reservation no
Maintenance Plan Notifications type preventive
Order
maintenance
Maintenance Supervisor
N N
Close PM03
Preventive Close PM
Maintenance Notification
Order
N
Technician
Execute
Work
Goods
Purchase
MM
Process Steps:
Business Situation
The Engineering maintenance Engineer will prepare the frequency & preventive maintenance
plan for the technical object which required for maintenance.
Based on preventive maintenance schedule maintenance HOD will prepare the maintenance
schedule plan for one month for better monitoring.
Schedule chart is prepared and distributed to Foreman/Supervisor, Production head and Engi-
neering head.
As per the recommended schedule plan, machine checklist will be issued to the foreman for
executing all the activities based on the check list.
All the information will be updated in the Maintenance orders of technical objects.
Scope
None Identified
Forms
None Identified
Reports
The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.
Conversions
# Requirement Description
3 AAHG-PM-CON-003 Task List
4 AAHG-PM-CON-004 Preventive Maintenance Plan
None identified
Workflows
None identified
7 Solution Design
The purpose of this section is to describe configuration required in Materials Management in
SAP.
30 PM03(Preventive Mainte-
nance order)
30 PM04(Refurbishment Order)
30 PM05(Calibration Order)
8 Gaps
None Identified
9 Enhancements
None Identified
10 Annexure -1 : Layouts
None Identified
None Identified