Plant Maintenance

Level-II Training

By Dhananjay Kedari

Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.

High Level Business Processes

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Preventive Maintenance ( In-House)

Create Maintenance plan Schedule Maintenance Plan

List of Notification

Notification

Call Object (Notification / Order)

Create order from notification list

Plannin

Order

Maintenance Order (Operations , Material, Labour, Tools

Maintenance order released to shop floor

Order Scheduling

Order Confirmation Order Execution

Good movement Time confirmation

Notification Completion
Cause Damage Activity Order settlement

Order Completion
Technical completion

History
Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.

Material usage, orders, notifications, PM-IS, usage list

Preventive/ Predictive Maintenance ( AMC with External Agency)

Create a settlement order for referenceobject

Create a Maintenance plan

G/L account Service specification

Schedule Maintenance Plan

Create a framework order (MM)

Vendor Value limit

Service Entry Sheet

Execution by vendor

Service entry sheet is updated for Purchase order

Purchase order (Service entry sheet)

Service entry sheet acceptance/Order Completion

Order settlement Technical completion

History Material usage, orders, notifications, PM-IS, usage list

Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.

Breakdown Maintenance ( In-House)

Notification
Date Technical object

User / Production

Details

Malfunction

Order Creation and Planning Maintenance Planner Maintenance Order

Operations Material Tools

Internal/external resources

Maintenance Planner

Maintenance order released to shop floor

Order release Shop Papers

Order Scheduling
Capacity leveling Availability check

Maintenance Work Center

Order Confirmation Order Execution

Good movement confirmation Time & activity

Maintenance Planner
Cause

Notification Completion
Damage Activity

Order Completion
Order settlement Technical completion

History Material usage, orders, notifications, PM-IS, usage list

Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.

Breakdown Maintenance ( External Agency)

Maintenance order Actual costs

Completion

Op. 10: Internal processing

Confirmation Purchase Requisition

Op. 20: External processing Purchase order (Service entry sheet)

Service confirmation Actual costs Goods receipt

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Equipment Sent Out for repairs

SAP R/3 Create/Process Order
Step Process steps System Agency

Create refurbishment order: After viable quantity of defective materials gets collected from the shops, which were received, 1 into stores with damaged valuation type, a refurbishment order has to be created. Process the Order: Required Operations are planned in the order. Materials to be refurbished are issued to the order in Maintenance / reconditioning dept. Maintenance / reconditioning dept. SAP Maintenance / reconditioning dept.

Plan and Schedule Order

Put Order in Process

Post Material Movements

damaged valuation type. Spares / materials required for refurbishment activity are requested through order.

SAP

Post External Services

Purchase requisition for external refurbishment has to be generated from order. Purchasing Document refurbishment: After the selection of vendor, if it is a one-time requirement purchase order is created.

SAP

Confirm Time

Settle and Complete Order

If it is a long-term/repeated requirement, scheduling lines are created from an existing scheduling agreement or purchase order is created from an existing contract.

SAP

Purchasing

Perform Evaluations in Plant Maintenance Information System [PMIS]

5 6

Goods receipt at stores: for incoming refurbished material. Payment for refurbishment: Payment is made to the vendor for the services delivered Complete the order: The maintenance confirms the job completion by closing the order for time & work confirmation. Goods receipt at stores: Refurbished goods are received into

SAP

Stores Finance Maintenance / reconditioning dept.

SAP SAP

stored with refurbished valuation type. Financial treatment for the order: Refurbishment order is settled

SAP

Stores

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using cost elements. Moving average price of refurbished valuation type is changed due to order settlement.

SAP

Costing

Creation of Maintenance order

Make Excise Chalan if necessary

Auto generation maintenance order

Service

PR

through Send goods to vendor for rerepairs rerepairs repairing

If AMC/ ARC is existing

Purchase Dept make enquiry & create PO

Receive the repaired goods

Are spares required for repair? Contract /FO reference to be mention in PR

Create PR & PO for regularizing material purchase

Print/make Advice

Dispatch PM user will create & accept service entry sheet

Store will make GR based vendors bill

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Equipment Calibration by External Agency

Create Task List with Inspection Characteristics Send Out material & receive cal.

Create Maintenance Plan

Trigger PM Order through Deadline Monitoring / manual

Service entry sheet creation after calibration

Inspection Lot generated automatically

Result Recording for Inspection Lot

Planning the services & Service PR generation Purchase order to the vendor

Business Completion of Order

Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.

In House Equipment Calibration

Create Task List

Create Maintenance Plan

Trigger PM Order through Deadline Monitoring/ manual

Release order & execute job

Creation measurement document for results

Confirm Actual Time for Operations

Enter Usage Decision

Business Completion of Order

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External Certification Services

Create Task List with Inspection Characteristics

Create Maintenance Plan

Trigger PM Order through Deadline Monitoring

Hiring of external agency by creating PR

Confirm Actual Time for Operations

Purchase order creation

Technical Completion of Order

Service entry sheet approval

Business Completion of Order

Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.

THANK YOU!!

Copyright 2009 Tata Technologies. All rights reserved. All other trademarks are trademarks of their respective owners.