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PLANT MAINTENANCE SYSTEM
Presentation Title | Confidential | Document ID
| 10-Dec-13
PLANT MAINTENANCE SYSTEM
I. MANAGING MASTERS II. MANAGING MAINTENANCE PROCESSES III. MANAGING REPORTS
| 10-Dec-13
I. MANAGING MASTERS
| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS CONTENTS OF MAINTENANCE OF MASTERS
1. Functional Locations 2. Equipment Master 3. Class & characteristics
4. MICs
5. Work Center 6. Measuring Point 7. Task List Master 8. Maintenance Item 9. Maintenance Plan
Plant Main Planner Group Plant Section Main Work Center Cost Center /Internal Order Category Company Code Strategy UOM
| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS CONTENTS OF MAINTENANCE OF MASTERS
1. Functional Locations 2. Equipment Master 3. Class & characteristics Function Location Structure
4. MICs
Function Location Category

Plant
| 10-Dec-13
FUNCTIONAL LOCATION STRUCTURE

Functional locations Structure is a hierarchical Presentation of a Tech. System. Gives information about how the Technical System is sub divided into Individual Functional Units. Individual function Units are defined on the Basis of Process Orientation, Functions, or any other Special criteria. Each functional location is managed independently in the system, so that you can : Manage individual data from a maintenance perspective for the object Perform individual maintenance tasks for the object Keep a record of the maintenance tasks performed for the object Collect and evaluate data over a long period of time for the object
| 10-Dec-13
FUNCTION LOCATION STRUCTURE

Description Structure Indicator Structure Indicator Text Edit Mask Hierarchy Levels Code GIL GIL Cement Division AAA-AANN-AAX-AAX-XXX-XXXXX 1 2 3 4 5 6
Example
Hierarchy Level Level 1 Level 2 Level 3 Level 4 Level 5 Level 6
8
Edit Mask AAA AANN AAX AAX XXX XXXX
Code GIL RC01 RC1 CM1 FEG
Description Grasim Industries Limited Raja shree Cement Raja shree Cement Unit-I RC1 Cement Mill-1 RC1 Cement Mill -1 Feeding Group
| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS CONTENTS OF FUNCTIONAL LOCATION MASTER Function Location Structure Function Location Category Plant
4. MICs
| 10-Dec-13
FUNCTION LOCATION CATEGORY

Category C G H M N O T U Description Colony Functional Locations General Functional Locations Hierarchical Plant & Machinery F Locations Mines Functional Locations Office Functional Locations Power Generation F. Locations Utility Functional Locations
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| 10-Dec-13
NAVIGATE > SAP SCREEN
Display of Function Location-[IL03] List Editing of Function Location-[IH06] Display ( Multi Level) Function Location[IL07] DISPLAY CONTENTS:
Display Action Log Object Information
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF MAINTENANCE OF EQPT MASTER
4. MICs
Equipment Category Plant Functional Location Main Planner Group Tech. Object Type Plant Section Main Work Center Cost Center /Internal Order Company Code Class Warranty data
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| 10-Dec-13
EQUIPMENT CATEGORY
Defining Equipment Categories is a facility in SAP/PM to group the vast variety of Equipments that any manufacturing Organization can have in their Plant. One of the methods of grouping similar Equipments is to differentiate them on the
basis of their Use and / or the Function that they perform e.g.,
Electrical Equipment. In GIL, this is the basis of defining Equipment Category shown in the next two slides
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| 10-Dec-13
EQUIPMENT CATEGORY
CATEGO RY A C D E I M N EQUIPMENT AUTOMOBILE CIVIL OBJECTS DUMMY EQUIPMENTS ELECTRICAL EQUIPMENTS INSTRUMENT EQUIPMENTS MECHANICAL EQUIPMENTS MINES EQUIPMENTS EXAMPLES CARS/JEEP/MOBILE VAN BUILDINGS/CIVIL EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR TRANSFER. NOT TO BE USED MOTORS/TRANSFORMERS/SWITCH GEARS RTDS/PROXIMITY SWITCHES/FIELD INSTRUMENTS/PANELS GEAR BOXES/DPC/DBC/BELT CONVEYORS SHOVELS/DUMPERS/DRILLING MACHINES
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| 10-Dec-13
EQUIPMENT CATEGORY
CATEGOR Y
P Q
EQUIPMENT
PROCESS EQUIPMENTS QC TEST EQUIPMENTS
EXAMPLES
CYCLONES/HOPPERS CUBE TESTING MACHINE / COMPRESSIVE STR MACHINE CRANES TURBINE/ECONOMISER/BOILER COMPRESSOR/WATER PUMPS
R T U NOTE:
PRODUCTION RESOURCES/TOOLS TPP/DG EQUIPMENTS UTILITY EQUIPMENTS
ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.
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| 10-Dec-13
EQUIPMENTS CATEGORY & NUMBER RANGE

Categor y M E I P T N A C S Q Number range From 10000000 20000000 30000000 40000000 50000000 60000000 70000000 80000000 90000000 1000000 Number Range To 19999999 29999999 39999999 49999999 59999999 69999999 79999999 89999999 99999999 1999999
Description
Mechanical Equipments Electrical Equipments Instrumentation Equipments Process Equipments TPP & DG Equipments Mines Equipments Automobiles Equipments Civil Objects & General Equipt. Safety Equipments QC Test Equipments
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| 10-Dec-13
TECHNICAL OBJECT TYPE
Technical Object Types are the logical grouping of Objects on the

basis of similarity of function being performed by each one.
Examples :
ME_GEARBOX EL_MOTORS ME_FANS Gear Box Electrical Motors Fans
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| 10-Dec-13
PLANNING PLANT
Plant in which maintenance tasks are planned and executed. In GIL , Planning Plant is also a Maintenance Plant. Different Planning Plants in GIL are : Aditya Cement Grasim Cement Vikram Cement Rajashree Cement Grasim South Birla Super Cement (Hotgi) Birla Plus Cement (Bhatinda)
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| 10-Dec-13
MAIN WORK CENTER

Main Work Center is Logical Grouping of all Work Centers, which are Performing similar nature of Maintenance Tasks/Activities in different Plant Sections. E.G. Mechanical Main Work Center is a Group of Plant Maintenance Persons, who are executing Mechanical Maintenance activities . Different Main Work Centers defined are :
Mechanical Department Electrical Department. Instrumentation Department. Process Department. Civil Department, Etc.
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| 10-Dec-13
PLANT SECTION
Plant Section is a division of Maintenance Plants into Production Areas.
Plant
GC01 GC01 GC01 GC01 GC01
Category
Description
RM1
CO1 KL1 CM1 PP1
Raw Mill -1
Coal Mill -1 Kiln -1 Cement Mill -1 Packing Plant -1
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| 10-Dec-13
PLANNER GROUP
Planner Group defines the Group of People (Employees) responsible for Planning and Execution of Maintenance Activities in a Particular Plant.
PLANNER GROUP CODIFICATION LOGIC PLANNER GROUP = MCM ECM ICM = = = MAIN WORK CENTER + PLANT SECTION Mechanical Electrical Instrumentation + + + Cement Mill Cement Mill Cement Mill
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| 10-Dec-13
COST CENTER/ INTERNAL ORDERS

Cost Centers are logical Organizational Units where the costs are incurred for value addition . Costs incurred are ultimately settled to Cost Centers through Orders. Internal order is nothing but an intermediate cost collector between PM order and cost center. Internal Order will be used in Mines Equipment only. Cost Center Concept as applied in GIL : Plant Section = Superior Cost Center Department = Sub Cost Center in that Plant section
CEMENT MILL
Mechanical
Electrical
Instrumentation
Process
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| 10-Dec-13
Creation of Equipment-[IE01] Change of Equipment-[IE02] Display of Equipment-[IE03] List Editing of Equipment-[IH08] Display ( Multi Level)-[IE07]
DISPLAY CONTENTS:
Display of Usage List Display Action Log Display Object Information Installation & Dismantle
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF CLASS & CHARACTERISTICS MASTERS
Class Type Class Group Characteristics Group
4. MICs
Unit of Measure for

Characteristics Master
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| 10-Dec-13
CLASS
Classes are :
Logical Grouping of Equipments having Similar Functions. Class Mainly Depends on the Main Function / Activity being Performed by that Equipment. It helps to know the Number of Equipments having the same Class. Class data will never Change throughout the entire Productive Life-Cycle of the Equipment. This information can be used for Proper Planning of Spares, for planned Maintenance & obtaining the History of that Class of Equipments.
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| 10-Dec-13
CHARACTERISTICS
Characteristics are the Specifications or Designed Parameters of Measurement for the Equipments. Ex. Flow of Fan , Gear Ratio of Gear Box. Combination of Class and Characteristics helps in Precise search of Equipments. For Example:
Select Gearbox of Particular Make / Ratio. Select Class as Gearbox & Characteristics as Make/ Ratio. Enter Relevant Values of these Characteristics. System will search & display all Gearboxes satisfying above Characteristics Values
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| 10-Dec-13
CLASS
Mechanical
Class Description
Electrical
Class
LTMOTOR LTFEEDER BATTERY BREAKER
Description
LT MOTOR LT FEEDER BATTERY BREAKER
GEARBOX
BUCKETELELVATOR BALLMILL
GEARBOX
BUCKET ELELVATOR BALL MILL
BAGHOUSE
BAG HOUSE
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| 10-Dec-13
CLASS AND CHARACTERISTICS GROUPS CODES

Class Group Code Description
PM_EQ_ELEC PM_EQ_GENL PM_EQ_INST PM_EQ_MECH PM_EQ_MINE PM_EQ_PROC PM_EQ_TPDG SA_EQ_SAFE PM Elec. Equipm ents Specs . Clas s Group PM General Equip. Specs . Clas s Group PM Ins t. Equipm ents Specs . Clas s Group PM Mech. Equipm ents Specs . Clas s Group PM Mine. Equipm ents Specs . Clas s Group PM Proc. Equipm ents Specs . Clas s Group PM TPP & DG Equip. Specs . Clas s Group PM Safety Equip. Specs . Clas s Group
Char. Group Code Description

PM_EQ_ELEC PM_EQ_GENL PM_EQ_INST PM_EQ_MECH PM_EQ_MINE PM_EQ_PROC PM_EQ_SAFE PM_EQ_TPDG
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PM Elec. Equipments Specs.Char. Group PM General Equip. Specs. Class Group PM Inst. Equipments Specs.Char. Group PM Mech. Equipments Specs.Char. Group PM Mine. Equipments Specs.Char. Group PM Proc. Equipments Specs.Char. Group PM Safety Equip. Specs. Char Group PM TPP & DG Equip. Specs. Char. Group
| 10-Dec-13
Display of Class List [CL03]

Find Object in Class- [CL30N ]
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF MICs MASTER
Plant
Range of Characteristics Value
4. MICs
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| 10-Dec-13
MASTER INSPECTION CHARACTERISTCS Specific parameters of an Equipment for Calibration Parameters to measure whether Equipment is performing its function
The Parameter driving / governing Equipment performance/Output is

within acceptable limits. Example: Mili-amperes / Mili-volts for weigh Feeder
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| 10-Dec-13
Find out The Maintenance Inspection Characteristics prepared-[QS24]
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF WORK CENTER MASTER
Plant Work Center Category Control Key
4. MICs
5. Work Center
Cost Center
Work Dimension - Time Work Unit
6. Measuring Point 7. Task List Master 8. Maintenance Item 9. Maintenance Plan
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| 10-Dec-13
WORK CENTER
Work Center is a Person/Group of Persons, who perform Maintenance Activities.
Work Center Category Each Department will have two categories, Permanent and Contractor. Category Description 0021 Mechanical Permanent 0022 Mechanical Contractor Example : M1F1W3K, MC1F1W3K etc. Codification Logic : M1F1W3K MC1F1W3K = Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi = Mech. Contractor / 1 Fitter /1Welder / 3 Khalasi
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| 10-Dec-13
Work Center List-[IR03] DISPLAY CONTENTS:

Relevant Number for Permanent and Contractor Work centers for your department. Different combinations of Skills.
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF MEASURING POINT MASTER
Equipment Master Function Location Master Category of Measuring Point
4. MICs
Characteristics
Unit of Measures
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| 10-Dec-13
MEASURING POINT It is a Measurement characteristic/Parameter attached to an Equipment Describe the Physical and/or Logical Locations of Equipment at which a Condition / Parameter is to be measured. Measuring Point will be always for an Equipment or FL or assembly but Generally for Equipments. Measurement readings are taken for an Equipment at regular interval to know the Condition at that time.
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| 10-Dec-13
MEASURING POINT
Continued..
Measuring Point is also Used as Counter where values Measured by a Measuring Point can be summed up during a time period for monitoring and control . Example: Running hours of Any Equipment Lubrication Consumption.
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| 10-Dec-13
NAVIGATE > SAP SCREEN(MP)
Creation Of Measuring point [IK01 ]
Change / Display Of Measuring Point [IK02/ IK03] Display List Editing-[IK07] Create Entry List-[IK31] Collective entry of measuring document-[IK34]
DISPLAY CONTENTS:
Transfer of Measuring point
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS BASIC CONTENTS OF TASK LIST MASTERS Group Coding Counter Planning Plant
1. Function Locations 2. Equipment Master 3. Class & characteristics
4. MICs
Maintenance Strategy
Work Center Set of Operations MIs
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| 10-Dec-13
TASK LIST
A Set of Activities to be Performed on an Equipment or Functional Location.

Three types of Task Lists : Functional Location Task List[T] Equipment Task List[E] General Task List[A]
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| 10-Dec-13
TASK LIST CODIFICATION

seq 1 Codification Logic for defining Task List Group - It has to be Planning Plant / Maintenance Specific
XX
GIL Plant Short Code: RC = RC01, GS = GS01, GS = GS01, GC = GC01, BS = BS01.
Discipline: E = Electrical, M = Mechanical, I =Instrumentation, P = Process, N = Mines, T = TPP, Q = QC,S = Safety
XX
Equipment Short "Equipment Class Code": GB = Gear Box, BF= Bag Filter, BC = Belt Conveyor, AT = Analyzer, MO= DC Motor, etc
Equipment Class Code Type( application) : GB Gear Box Helical; Radial; BE-Bucket Elevator Belt/ Chain
XX
Type of Maintenance Task List: PM=Preventive Maintenance , AM = AMC Tasks, CA= Calibration ; SD = Shutdown , IN = Inspection (attribute/Value EN-Environment;) J-Jishu Hozen ( General Inspection ) ZXSafety
Example:
GCMGBHPM GCEMODPM
GCM-GBH-PM 1M Checks GCE-Motor-DC-PM 3M Checks
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| 10-Dec-13
MAINTENANCE STRATEGY
Set of Predefined Prefixed Time Intervals ( Called Packages) grouped at Which Preventive Maintenance Activities can be taken Up. These Maintenance Strategies can be selected By User to carry out Maintenance Activities depending Upon :- Age of Equipment Design of Equipment Importance of Equipment in Production Process Maintenance Practices of Organization.
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| 10-Dec-13
MAINTENANCE STRATEGIES
Continued..
GILDAY -- Frequencies Specified in GILDAY
Are 1W / 2W / 1M / 3M / 6M / 1Y GILMON-- Frequencies Specified in GILMON Are 6M/ 1Y/ 2Y/ 5Y MINEHR -- Frequencies Specified in MINEHR Are 100HR/ 300HR / 350HR/ 400HR PERFHR -- Frequencies Specified in PERFHR Are150HR / 250HR / 500HR/ 1000H
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| 10-Dec-13
APPLICATION:
Continued..
GILDAY: Strategy is Used for Frequencies of Check Up to 6M.
GILMON: Strategy is Used for Frequencies of Checks More than 6M. MINEHR: Strategy is Used For MINES Preventive Maintenance Planning. PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance Planning.
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| 10-Dec-13
MAINTENANCE PACKAGE
Strategy GILDAY
Cycle Length
7 14 28 84 168
UOM
DAY DAY DAY DAY DAY
Maintenance Cycle Text

Weekly (1 Week ) Fortnightly (2 Weeks ) Monthly ( 4 Weeks ) Quarterly ( 12 Weeks ) Half yearly ( 24 Weeks )
Cycle Short Text

1W 2W 1M 3M 6M
336 Strategy GILMON
DAY
Yearly ( 48 Weeks )
1Y
Cycle Length
6 12 24 48
UOM
MON MON MON MON

Half yearly Yearly 2 Yearly 5 Yearly
Cycle Short Text

6M 1Y 2Y 5Y
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| 10-Dec-13
MAINTENANCE PACKAGE
Strategy MINEHR
Continued..
Cycle Length
96 312 360 408 504 1008 1512 2016 2496 3000
UOM
HR HR HR HR HR HR HR HR HR HR

100 Running Hours ( 96 Hrs) 300 Running Hours ( 312 Hrs) 350 Running Hours ( 360 Hrs) 400 Running Hours ( 408 Hrs) 500 Running Hours ( 504Hrs) 1000 Running Hours (1008 Hrs) 1500 Running Hours (1512 Hrs) 2000 Running Hours (2016 Hrs) 2500 Running Hours ( 2496 Hrs) 3000 Running Hours ( 3000 Hrs)
Cycle Short Text

P1 P2 P3 P4 P5 P6 P7 P8 P9 1P
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| 10-Dec-13
MAINTENANCE PACKAGE
Strategy PERFHR
Continued..
Cycle Length
UOM
Cycle Short Text
144
240 504 1008 2496 4032 8064 12096 16128 24192
HR
HR HR HR HR HR HR HR HR HR
150 Running Hours ( 144 Hrs.)

250 Running Hours ( 240 Hrs.) 500 Running Hours ( 504 Hrs.) 1000 Running Hours (1008 Hrs) 2500 Running Hours (2500 Hrs) 4000 Running Hours (4032 Hrs) 8000 Running Hours (8064 Hrs) 12000 Running Hours (12096 H) 16000 Running Hours ( 16128 H 24000 Running Hours ( 24192 H
P1
P2 P3 P4 P5 P6 P7 P8 P9 1P
32256
HR
32000 Running Hours ( 32256 H
2P
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| 10-Dec-13
Display Task List-[IA07]
List Editing Task List-[IA09]
DISPLAY CONTENT: Find Task Lists in your Planner group.
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF MAINTENANCE ITEM MASTER
Equipment /Function Location Master Task list Master Strategy
4. MICs
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| 10-Dec-13
MAINTENANCE ITEM
Maintenance Item describe Preventive Maintenance Tasks to be performed on an Equipment at Predefined Interval
Maintenance Item = Equipment + Task List with set of operations with Maintenance Package
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| 10-Dec-13
MAINTENANCE MASTERS
BASIC MASTERS
BASIC CONTENTS OF MAINTENANCE PLAN MASTER
Maintenance Item Master Strategy Scheduling parameter
4. MICs
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| 10-Dec-13
MAINTENANCE PLAN
Maintenance Plan is the Scheduling of Task List attached to an Equipment (Maintenance Item ) on Time Scale ( According to Factory Calendar ) or Performance scale ( According to Counter i.e. Number of Hours).
Plan = Maintenance Item + Scheduling Parameters
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| 10-Dec-13
MAINTENANCE SCHEDULING PARAMETER

TOLERENCE: ( 50% ) It is the difference between planned date and TECO date ,given in %age for deciding whether maintenance cycle should be shifted or not, considering the gap between planned date and TECO date. Shift factor will be effective only if difference between planned date and TECO date is more than 50% of smallest interval (smallest package) , either + or side. If difference between planned date and TECO date is less than 50% of smallest interval (smallest package) , there will be no shift. For GILDAY , it will be + / - 3.5 days , as minimum frequency is 1w. For GILMON it will be +/- 3 months as min freq is 6M. SHIFT: 100% . If condition given in Tolerance is true it will shift the maintenance cycle by : given shift % x difference between planned date and TECO date .i.e. Actual
delay
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MAINTENANCE SCHEDULING PARAMETER

CALL HORIZON 50%
Continued..
It indicates that an advance intimation of planned maintenance will be given by 0.5 x minimum frequency of strategy selected through order generation . FOR GILDAY : 1W Being minimum frequency , you will get weekly order 3.5 days in advance if call horizon is 50%.
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| 10-Dec-13
II. MANAGING MAINTENANCE PROCESSES
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| 10-Dec-13
MAINTENANCE PROCESSES
BASIC PROCESSES
BASIC STEPS OF MAINTENANCE PROCESSES
1. Preventive Maintenance 2. Break down Maintenance 3. Shut down Maintenance 4. Condition base Maintenance 5. Work shop Repair
6. External Repair/Services
7. Calibration
Creation of Notification Creation of Orders Execution of Orders Confirmation of Orders Technical Confirmation of Orders Creation of Purchase Request Creation of Purchase Orders Service Entry Sheets Creation of Measuring Points & Measuring Documents Installation / De-installation of Equipments
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| 10-Dec-13
1. PREVENTIVE MAINTENANCE PROCESS

BASIC PROCESSES
1. Preventive Maintenance 2. Break down Maintenance 3. Shut down Maintenance
BASIC STEPS OF PREVENTIVE MAINTENANCE PROCESS
Selection of Orders Execution of Orders
4. Condition base Maintenance

5. Work shop Repair 6. External Repair/Services
Confirmation of Orders
Technical Completion of Orders
7. Calibration
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| 10-Dec-13

Selection of Order
H/L TO ORDER TYPES
BASIC STEPS OF MAINTENANCE PROCESSES Selection of Orders
Go to T. Code - IW39 Flag Outstanding & In process check box Enter Order Type PM01
Select from Drill Down
Execution of Orders
Confirmation of Orders Technical Completion of Orders
Enter Period ( Date from..to ) Enter Status exclusive in Multiple Selection

Enter Maintenance Plant Enter Planner group for Order Execute by clicking button Order list of relevant section Appears
Select from Drill Down CRTD, CNF , TECO & CLSD
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ORDER TYPES
PM01 --- PREVENTIVE MAINTENANCE ORDERS These Orders are Planned by SAP System
User can not generate PM Work Order for this Order Type externally.
This Order type will help User to find out Cost of Preventive Maintenance exclusively for his Plant section/Planner group. User will be able to compare Cost Of Preventive Maintenance vis--vis Breakdown and Shutdown Maintenance. User will be able to judge the effectiveness of Preventive Maintenance Plans by this Order Type. Order Numbering is blocked for this Order
User will get Preventive Maintenance Orders under Maintenance Activity Type PVM , Annual Maintenance Contract Orders under Maintenance Activity Type AMC and Inspection Orders under Maintenance Activity Type INW
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| 10-Dec-13
ORDER TYPES
Continued..
PM02: BREAKDOWN MAINTENANCE ORDERS

This Order Type is exclusively for Breakdown registration of Equipments This Order Type indicates Unplanned stoppage in Production Process
In addition to consumption of Recourses like Men , Machine , Material , Production loss is also associated with this type of Order .
User can further segregate the breakdowns of Equipments under Warranty / Insurance from other Breakdowns. PM03: SHUTDOWN MAINTENANCE ORDERS This Order Type indicates Annual Shutdowns ( Maintenance Activity Type: SDM) Planned Weekly,Fortnightly,Monthly Stoppages ( Maintenance Act. Type : WFM) Opportunity Based Maintenance (Maintenance Activity Type: OPP)
The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be booked under MAT- SDM.
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ORDER TYPES
PM03: SHUTDOWN MAINTENANCE ORDERS
Continued..
Only Planned Weekly,Fortnightly,Monthly Stoppages will be booked under Maintenance Activity Type WFM Other Maintenance jobs not planned but undertaken because of availability of Opportunity are booked under MAT-OPP. PM05: CALIBRATION MAINTENANCE ORDERS This Order Type is applicable for Calibration of Equipments These Orders are Planned by System . However , User can also raise Order externally , if required for unplanned Calibration jobs. This Order Type has MAT- CAL . PM06 : CORRECTIVE MAINTENANCE ORDERS The jobs covered under this Order Type are of 2 types: Corrective Actions suggested under WHY-WHY Analysis to avoid recurrence of Breakdown will be covered under Maintenance Type WHY .
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ORDER TYPES
Continued..
PM06 : CORRECTIVE MAINTENANCE ORDERS Other Maintenance Jobs of Corrective Nature e.g. Maintenance Requests from other departments , Removal of Abnormalities/Defects, Removal of Unsafe Conditions where Breakdown has not occurred will be covered under MAT- CRM PM07 --- CONDITION BASED MAINTENANCE ORDERS This Order Type is applicable for jobs planned on the basis of Condition of Spares. E.g. Replacement of Worn Out Chain/ Worn-out Hammers etc MID , being Condition Monitoring Department , will use this Order Type for advising repair / replacements on the basis of Condition E.g. Hardness/Thickness/Vibrations etc PM08 --- GENERAL MAINTENANCE ORDERS This Order Type is applicable for UNDEFINED jobs NOT FALLING under above categories and not related to Equipment. E.g. Leakage of Water Tap in Administration Building garden. These are of Minor nature Repair Jobs. This Order Type should not be used unless it satisfies above condition
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ORDER TYPES
PM09: REPAIR MAINTENANCE ORDERS
Continued..
There are Four different Activity Types or jobs covered under this category. They are:
Work Shop jobs should be registered under MAT RWS Rewinding jobs should be registered under MAT - REW Tyre Retreading jobs should be registered under MAT RET External Repair jobs should be registered under MAT RVN PM10: IMPROVEMENT/MODIFICATION ORDERS All jobs of Improvements and Modifications in Maintenance (Reliability MTTR/MTBF/Maintainability/Availability) are covered under Maintenance Activity Type IMO Suggestions given by Consultants/Experts/Other Units/ Other sources like Websites, Manuals, Magazines etc are covered under Maintenance Activity Type CON. PM11: CAPEX/BLOCK ORDERS All Work Orders raised for Project Work are covered under this Order Type and MATCAP PM12 --- CIVIL MAINTENANCE ORDERS All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/ Foundation Presentation Title | Confidential Document ID | 10-Dec-13 etc are covered under| this Order Type and MAT-CIV
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MAINTENANCE ACTIVITY TYPES IN PM ORDERS

Order Type PM01 PM02 PM03 PM05 PM06 PM07 PM08 PM09 PM10 PM11 PM12 QCAL Description Preventive Maintenance Order Breakdown Maintenance Order Shutdown Maintenance Order Calibration Order Corrective Maintenance Order Condition Based Maintenance General Maint Order Repairs Order Improvement/Modification Order Capex / Block order Civil Maintenance Order QC Insp./ Calibration Order Order Activity Type PVM,AMC,INW BDM,WAR,INS SDM,OPP,WFM CAL CRM,WHY CBM GEN RWS,RVN,RET,REW IMO.CON CAP CIV CAL
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Selection of Order
H/L TO ORDER TYPES
BASIC STEPS OF MAINTENANCE PROCESSES Selection of Orders
Go to T. Code - IW39 Flag Outstanding & In process check box Enter Order Type PM01
Execution of Orders
Enter Period ( Date from..to ) Enter Status exclusive in Multiple Selection

Enter Maintenance Plant Enter Planner group for Order Execute by clicking button Order list of relevant section Appears
Select from Drill Down CRTD, CNF , TECO & CLSD
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BASIC STEPS OF MAINTENANCE PROCESSES Selection of Orders Execution of Orders Confirmation of Orders Technical Completion of Orders
Select desired order Move to SAP Screen
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Execution of Orders
Go to T. Code - IW32 Enter number of Selected Order Release PM01 Type Selected Order Go to Operation TAB and Change operations etc if reqd Select operation & Go to Component TAB if Material Required Select required Component Enter reqd Qty , Item category, Storage Location & Batch Come to Header data Tab Enter Start Date & Time
Order status will be changed to REL from CRTD
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| 10-Dec-13

Schedule Order by Clicking Determine cost by clicking Save the Order Move to SAP Screen
End date & time will be changed by system
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Confirmation of Order
Go to T. Code IW44 Select Header Menu Confirmation Select via operation list in Confirmation Menu Selection of operation list appears Enter Plant
Selection of Orders
Execution of Orders Confirmation of Orders Technical Completion of Orders
Enter Order type

Enter Reference date Enter Planner group Enter Status Exclusive in Multi Selection List
70 Presentation Title | Confidential | Document ID | 10-Dec-13
CRTD, CNF , TECO & CLSD

Execute by clicking button All relevant Orders with Operations will be copied on main screen Select All Operations Click All Actual Data on Header Tool bar All Planning data of operations defaulted from relevant Orders Enter Actual Work Center Qty Flag Final confirmation, Clear all Res & No remaining work Enter Start Date & Time Enter End Date & Time
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Enter Actual Duration
Enter Confirmation Text

System will calculate Actual Duration Save Confirmation by clicking Move to SAP Screen
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Technical Completion of Order Go to T. Code - IW32 Selection of Order Screen appeared Flag In process check box Enter Order Type PM01 Enter Period (Date fromto) Enter Status exclusive in Multiple Selection Enter Maintenance Plant Enter Planner group for Order Execute by clicking button
Select from Drill Down CRTD, REL , TECO & CLSD
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BASIC STEPS OF MAINTENANCE PROCESSES Selection of Orders Execution of Orders Confirmation of Orders Technical Confirmation of Orders
Order list of relevant section Appears Select order and click Order Main Header Screen Opens Click Settlement Rule button Enter / change cost center & give % if required Click Flag of Technical Completion Enter Reference Date & Time Click Enter Button
Order is Technically Completed & System Status Changed to TECO Move to SAP Screen
2. BREAKDOWN MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF BREAKDOWN MAINTENANCE PROCESS Creation of M2-Notification Selection of M2-Notification Creation of PM02-Order Selection of Order Execution of Orders Confirmation of Orders Technical Completion of Orders Execution & Completion of

7. Calibration
Notification Why-Why Analysis
75
| 10-Dec-13

BASIC STEPS OF MAINTENANCE PROCESSES Creation of M2-Notification Selection of M2-Notification Creation of PM02-Order Selection of Order Execution of Orders Confirmation of Orders Technical Completion of Orders Execution & Completion of Notification Why-Why Analysis
Notification Tab Screen Appears
Click Enter Button Enter Notification Description Enter Equipment / FL / Assembly (as required) Enter Reported By (Name) Creation of M2 Notification Go to T. Code IW21Create Notification Enter Notification Type Do not Enter Notification Number
H/L TO N/F Types
Manual Process
System Generated
76
| 10-Dec-13
NOTIFICATION TYPES
M1 --- MAINTENANCE REQUEST
Continued..
This Notification type indicates a request made by Customer department to his Supplier/Service Provider. E.g Request made by Raw Mill Mechanical for repair of Gear Box shaft on Workshop. This includes all types of jobs of Maintenance/Repair/Service requests made by User on Service Provider EXCEPT Malfunction/Breakdown.
M2 --- MALFUNCTION/BREAKDOWN
This Notification Type is exclusively for information regarding Breakdown of Equipments This Notification is raised generally by Production on relevant Maintenance Department as a FIR of Unplanned stoppage in Production Process. However , anybody can raise this Notification if it satisfies above condition.
77
| 10-Dec-13
NOTIFICATION TYPES
M3 --- UNSAFE CONDITION/ACCIDENT
Continued..
This Notification is an information from any department including Safety regarding prevailing Unsafe/ Hazardous Condition which is dangerous and may cause damage to Property/Human being / Environment /Surroundings etc , to the relevant department responsible for such condition for necessary corrective action. M4 --- ABNORMALITY RECORD This notification is raised to register 7 types of Basic Defects in Equipments. These defects are revealed through Daily Check List/ Inspection/Plant Round Satisfies the WCM requirement to monitor 7 type of basic defects which are responsible for Breakdown , if not corrected in time.
78
| 10-Dec-13
NOTIFICATION TYPES
M5: RECOMMENDATION/IMPROVEMENT
Continued..
This Notification is generated by User for any improvement/development to be implemented . The source for Improvement/Modification/Development in Reliability/ Availability /Maintainability may be WHY-WHY Analysis, Experts/Consultants recommendation/Other Units/KIPs etc The number of such Notifications will be an indicator of improvements done by User These notifications will give List of Improvements done by User which is required by WCM or for sharing with other Units.
M6 --- WORK REQUEST-WORKSHOP
This notification is raised by User on workshop requesting its services for Repair/Machining/Replacement of Spares/Assembly/Equipment etc.
79
| 10-Dec-13
NOTIFICATION TYPES
Continued..
M7: GENERAL NOTIFICATION.

Notification which does not fall in any of the conditions mentioned above may be raised in this type. This type of Notification should not be used as far as possible as it will affect history/vital information about Equipments. M8: MEASURING POINT ERROR This notification is raised by the SAP system automatically whenever the Parameter defined as a Measuring Point deviates from its Standard Value or goes beyond its Acceptable Permissible Value.
80
| 10-Dec-13
Notification Types
Notification Type M1 M2 M3 M4 M5 M6
Description Maintenance Request Malfunction, B/Down UnsafeCond./Accident Abnormality Record Recommendation Work Request- W.Shop
Number Ranges From -To 1000000000 to 1999999999 2000000000 to 2999999999 3000000000 to 3999999999 4000000000 to 4999999999 5000000000 to 5999999999 6000000000 to 6999999999
81
| 10-Dec-13

Notification Tab Screen Appears
Click Enter Button Enter Notification Description Enter Equipment / FL / Assembly (as required) Enter Reported By (Name) Creation of M2 Notification Go to T. Code IW21Create Notification Enter Notification Type Do not Enter Notification Number
H/L TO N/F Types
Manual Process
System Generated
82
| 10-Dec-13

Release & Save the Notification In case of Main Plant, M2 Type Notifications will be Generated by System thru breakdown entry made by CCR Naviaget >SAP Screen
Popup Massage of warranty Prompts

Enter Code of STD TEXT Attached Main Work center/ Planner Group etc Defaulted & can be Changed If Required If Reqd Enter Long Text Go To Location Data Tab Flag breakdown check box
If equipment Under warranty
All information Defaulted from equipment master

Selection of M2 Notification
Go to T. Code IW28 Selection of Notification

Flag check box Outstanding or In process (as Reqd) Enter Notification Date Enter Planner group
Enter Maintenance Plant Click Enter Button List of Notifications Appears as per Selection Criteria Select relevant Notification Click on Details Button Notification Change Screen Appears
84
| 10-Dec-13
Navigate. SAP Screen

Creation of PM02 Type Order from Notification M2 Notification selected in Changed Mode as explained in pervious sheet
Click Create button

of Order Tab Create Order Popup Screen Appears with Defaulted data from notification Enter PMActType BDM & click continue button & save Breakdown Order Created Further process of order will remain same as explained in process 1. Preventive Maintenance Navigate> SAP Screen
85
| 10-Dec-13

Process of Selection of Order, Execution of Order, confirmation & TECO will be similar to processes explained in process 1. Preventive Maintenance
86
| 10-Dec-13

Execution of M2 Notification (Order not generated)
M2 Notification selected in Changed Mode as explained in pervious Process

To Attach Std Text Go to Effect field & select relevant code of Std Text Insert Text popup screen appears. On Insert Text screen Flag Expand immediately , enter Text ID ST & click on dropdown of Text Name field Next Popup screen Database selection for SAP script text Execute Popup screen Database selection for SAP script text without entering any data
Select from Drill Down Select from Drill Down
87
| 10-Dec-13

Select malfunction& downtime tab and Enter down time end Date &Time. Desired Standard Text Get copied in long text. Complete it & go back to main screen Now popup screen Insert Text appear again with text attached. Click Continue Button Next Popup screen Find SAP script text will appear. Select relevant text & click continue button
Click Complete Flag and complete Notification

Navigate> SAP Screen
88
| 10-Dec-13

BASIC STEPS OF MAINTENANCE PROCESSES Creation of M2-Notification
Selection of M2-Notification Creation of PM02-Order Selection of Order Execution of Orders Confirmation of Orders Technical Completion of Orders Execution & Completion of
Enter Plant , Plant Section & Planner group Enter Date Range (From...To) Select status by flagging and execute List of Notification appears (as per selection criteria) Select relevant notification & double click it Why Why Analysis screen Appears
Create Why Why Analysis Sheet Go to T. Code -- ZRPM-WHY
Notification
Why-Why Analysis
89
| 10-Dec-13

Enter Rectification carried out Enter Recommendations Enter Responsible person and Tar Date for Recommendations Select Document Attached - Say 2
Enter Object Code Enter Damage Code Enter all Possible Causes (Possible reasons) Flag YES box to actual Cause Enter Observations Enter Analysis In Why Why Field
Select from Drill Down Select from Drill Down Select from Drill Down

Save why-why Analysis Change Why Why Analysis Go to T. Code ZRPM_WHY Go to Main screen of selected Notifications why why analysis Click Put in Process Flag Next procedure of Standard text shall be similar as explained in Process Execution of M2 Notification Click Complete Flag and Complete Notification
Change Why Why analysis data as per requirement

Save changed why-why Analysis
| 10-Dec-13

91 Presentation Title | Confidential | Document ID
3. SHUTDOWN MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS Creation of PM03 - Shutdown Orders Selection of PM03 - Shutdown Orders Report of Shutdown Planning Creation of Direct Purchase Order Creation of Direct Purchase

7. Calibration
Request (Indent) Execution of Orders Confirmation of Orders Technical Completion of Orders
92
| 10-Dec-13

BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS Creation of PM03 - Shutdown Orders Selection of PM03 - Shutdown Orders Report of Shutdown Planning
Enter Equipment Number Equipment selection screen appears Enter Equipment Class (Optional) Equipment Category - M Maintenance Plant Enter plant Section Enter Planner Group Click Execute Button
Select from Drill Down Select from Drill Down Select from Drill Down Select from Drill Down Select from Drill Down By Drill Down go to selection screen
Creation of Shutdown Order Go to T. Code IW31 Enter Order Type - PM03

Creation of Direct Purchase

Order Creation of Direct Purchase Request (Indent) Report of Shutdown Planning
Execution of Orders
93
| 10-Dec-13

Select Desired Equipment & click . Equipment entered in field Enter Planning Plant & Enter Create Shutdown Maintenance Order : Central Header Screen appears Enter Order Description Go to Header data Tab & Enter PMActTYPE - SDM Go to Operation Tab and Enter Operations as required Enter Relevant Work Center Enter Relevant Control key Better to Create Separate Order for PMIN & PMEX Control key Pl Refer Next Slide

Order Creation of Direct Purchase Request (Indent) Execution of Orders
PMIN
After Assigning Control Keys
PMEX
Enter Work or Duration Enter WC Qty and Cal.Key Activity type Defaulted Select Operation & Go to Component TAB if Material Required Enter required Material, qty, S.Loc (see stock) & Batch Again Go to Operation screen Enhancement Button and enter Field key ZPM0001, Position Click Gen Data Button & Get Reservation Number on comp detail screen & come back
Select Operations Click on External Button Popup screen External Processing Operation appears Select Material Group ( S524 For External Services) & Pur. Group Enter Vender , tracking No & click External Processing operation Appears Go to service tab & Select Desired Services from Service Master or write Description only & Enter Required Quantity Enter Cost Element & Press Enter
95
| 10-Dec-13
Click scheduling & determine cost button For Release Order Press Icon Save Order by click button Navigate> SAP Screen
Enter Cost Element & Press Enter

Create Purchase Requisition screen appears. Enter Dept and Press Enter Repeat above three steps for Next Operation's Go to Header Screen & Click Determine cost button
You can See PR No Thru GEN data->Act data Tab
For Release Order Press Icon Save order by click button Navigate> SAP Screen
96
| 10-Dec-13

BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS Creation of PM03 - Shutdown Orders Selection of PM03 Shutdown Orders Report of Shutdown Planning Process of Selection of Order, Execution of Order, confirmation & TECO will be similar to processes explained in process 1. Preventive Maintenance

Order Creation of Direct Purchase Request (Indent) Report of Shutdown Planning
Execution of Orders
97
| 10-Dec-13

Report1. of Shutdown Planning Go to T. Code IW49N Display order & Operation: selection of order & Operation screen appears Flag Outstanding & In process Order Enter Order type Enter Main work center Enter Period (dates) Maintenance Plant Enter Plant Section Enter Planner Group
Select from Drill Down Select from Drill Down Select from Drill Down Select from Drill Down

98
| 10-Dec-13

Click Execute Button Report of Order with Operation etc Appears View Reports with Relevant Layout selection Navigate> SAP Screen

99
| 10-Dec-13

BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS Creation of PM03 -Shutdown Orders Selection of PM03 -Shutdown Orders Report of Shutdown Planning Creation of Direct Purchase Order Creation of Direct Purchase Request (Indent) Execution of Orders Confirmation of Orders
Report 2 of Shutdown Planning (MATERIAL) Go to IWBK Material Availability Check (for orders) Material availability Information screen Click Multiple Selection of Order Field Click Multiple selection button Flag outstanding & In process Enter Order Type- PM09 Enter Period (dates) Maintenance Plant Enter Plant Section Enter Planner Group

BASIC STEPS OF SHUTDOWN MAINTENANCE PROCESS Creation of PM03 -Shutdown Orders
Click Execute Button Report of Order with Operation etc Appears Go to back to Multiple selection screen & Execute
Selection of PM03 -Shutdown

Orders Report of Shutdown Planning Creation of Direct Purchase Order
Paste Selected Orders & execute

You will reach back to main screen of Material availability Information Click execute button again Screen of Availability list of Materials for Operations will appears On This Screen You Will Get Order wise Materials with Stock Availability status
| 10-Dec-13


101 Presentation Title | Confidential | Document ID

Creation of Direct Purchase Order (For Contractors) Go to T. Code ME21N Create Purchase Order

Orders Report of Shutdown Planning Creation of Direct Purchase Order (For Contractors)
Select Type of Purchase Order

Enter Vendor Code Enter Purchase Organization, Purchase Group & Company Code Go to item overview Tab and Enter Account Assignment K and Item category - D Enter Short text of Services Enter Material Group , Plant , tracking number (Employee) and Department (planner group)
Select from Drop Down Select from Drop Down thru Vendors : Purchasing Select from Drop Down

Select from Drop Down
Select from Drop Down. Search Tracking number thru Vendor by Company code
102
| 10-Dec-13

Go to Item Tab and Enter Services number , Qty Go to Account Assignment Sub Tab and Enter G/L Account number and Cost center Check entries by Clicking Button Correct Entries If error massage other wise Save the order Navigate> SAP Screen


103
| 10-Dec-13
4. CONDITION BASE MAINTENANCE PROCESS

BASIC PROCESSES
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of Measuring Point Selection of Measuring Point Creation of Measuring Document & Auto Notification Creation of Entry List Measuring Document Thru Entry list Selection of M8 type Notification Creation of Corrective Maintenance

7. Calibration
Order Thru Notification

Execution of Orders Confirmation of Orders Technical Completion of Orders
104
| 10-Dec-13

Creation of Direct Purchase Requisition (For Spare) Go to T. code ME51N -Create PR Enter PR Type & Header note Account Assignment Type U & Item Category leave Blank Enter Material & Reqd Qty Enter Del date , Plant & Tracking number (planner group) Check entries by Clicking Button Correct Entries If error massage other wise Save the Purchase request Navigate> SAP Screen

Select from Drop Down Select from Drop Down


BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point Selection of Measuring Point Creation of Measuring Document & Auto notification Creation of Entry List Measuring Document Thru Entry list Selection of M8 type Notification Creation of Corrective Maintenance Order Thru Notification Execution of Orders Confirmation of Orders Technical Completion of Orders
Presentation Title | Confidential | Document ID | 10-Dec-13
Creation of Measuring Point Go to T. Code - IK01 -Crete Measuring Point Select Measuring Point Object IEQ Select & enter Equipment number Select Relevant Measuring Point Category (Except L & F) Do not flag MP as counter for CBM Click on Enter Button
Write Measuring Position & Description
106

BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point
Enter relevant Characteristic (UOM & decimal Place defaulted) Go to Additional data Button header tool bar Enter Upper range limit & Lower range limit Click on Enter Button Main screen appears. Now click on Save button to save MP Navigate> SAP Screen
Selection of Measuring Point

Creation of Measuring Document & Auto notification Creation of Entry List Measuring Document Thru
Entry list
Selection of M8 type Notification Creation of Corrective Maintenance Order Thru
Notification Execution of Orders Confirmation of Orders Technical Completion of Orders

107

BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point Selection of Measuring Point Creation of Measuring Document & Auto notification
Selection of Measuring Point Go to T. Code - IK07 Display measuring Point : Measpoint Selection
Enter Characteristics & MP Category

Click Execute Button Measuring point list appears Select relevant Measuring point Navigate> SAP Screen
Creation of Entry List

Measuring Document Thru Entry list Selection of M8 type Notification Creation of Corrective
Maintenance Order Thru

Notification Execution of Orders Confirmation of Orders Technical Completion of Orders
108

BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point
Selection of Measuring Point Creation of Measuring
Creation of Measuring Document Go to T. Code IK11 - Crete Measuring Document Enter Measuring Point (as selected) Again Click on Enter Button Enter MeasRdg as taken from site Again Click on Enter Button A Massage Appears In case Reading is Outside range Again Click on Enter Button Main screen of M8 type Notification Generates Automatically
| 10-Dec-13
Document & Auto Notification

Creation of Entry List Measuring Document Thru Entry list Selection of M8 type Notification
Creation of Corrective
Maintenance Order Thru Notification Execution of Orders Confirmation of Orders Technical Completion of Orders
109

BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point Selection of Measuring Point Creation of Measuring Document & Auto Notification Creation of Entry List
Enter Reported by & click Enter button An Auto Notification of M8 type Created A massage comes for Measuring document Created Navigate> SAP Screen
Measuring Document Thru

Entry list Selection of M8 type Notification Creation of Corrective Maintenance Order Thru Notification Execution of Orders Confirmation of Orders Technical Completion of Orders
110
| 10-Dec-13

BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point Selection of Measuring Point
Creation of Entry List Go to T. Code IK31 Measuring reading entry list: Create Click on Enter Button Screen of Measuring reading entry list: Create Appears Enter entry list name & Description Enter measuring point numbers As selected from drop down list Click on Enter Button All details of Measuring points Appears in list Now Click on Save Button A Massage measurement reading entry list xxx saved. Navigate> SAP Screen
Creation of Measuring
Document & Auto notification Creation of Entry List Measuring Document Thru Entry list
Selection of M8 type
Notification Creation of Corrective Maintenance Order Thru Notification Execution of Orders Confirmation of Orders Technical Completion of Orders

BASIC STEPS OF CONDITION BASE MAINT. PROCESS Creation of Measuring Point Selection of Measuring Point Creation of Measuring Document & Auto notification Creation of Entry List Measuring Document Thru Entry list Selection of M8 type Notification Creation of Corrective Maintenance Order Thru Notification Execution of Orders Confirmation of Orders Technical Completion of Orders
Creation of Measuring Document Thru Entry list Go to T. Code IK34 Collective entry of MeasDocuments: Initial screen Enter Entry list number Click on Enter Button Collective entry of MeasDocuments: overview screen Appears Enter measuring Reading in relevant measuring point field Click on Enter Button A Massage Appears In case Reading is Outside range &click again enter button. M8 Notification will generate A massage appears as xx Measuring document Created
| 10-Dec-13
112
5. REPAIR MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF REPAIR MAINTENANCE PROCESS Creation of M6-Notification Selection of M6-Notification Creation of PM09-Order Selection of Order

5. Work shop Repair 6. External Repair/Services 7. Calibration
Execution of Orders Confirmation of Orders Technical Completion of Orders Execution & Completion of Notification
113
| 10-Dec-13

BASIC STEPS OF MAINTENANCE PROCESSES Creation of M 6-Notification Selection of M 6-Notification Creation of PM09-Order Selection of Order Execution of Orders Confirmation of Orders Technical Completion of Orders Execution & Completion of Notification
Enter Notification Description
Enter Equipment / FL / Assembly (as required) Enter Reported By (Name) Enter Code of STD TEXT Attached
Creation of M6 Notification
Manual Process
Go to T. Code IW21Create Notification

Enter Notification Type Do not Enter Notification Number Click Enter Button Notification Tab Screen Appears
H/L TO N/F Types
System Generated
Select from Drill Down as per requirement

Navigate> SAP Screen Save the Notification
Main Work center/ Planner Group etc Defaulted & can be Changed If Required Write Details of Job in Long Text Go To Location Data Tab
All information Defaulted from equipment master
115
| 10-Dec-13

BASIC STEPS OF MAINTENANCE PROCESSES Creation of M6-Notification Selection of M6-Notification Creation of PM09-Order Selection of Order Execution of Orders Confirmation of Orders Technical Completion of Orders Execution & Completion of Notification
Select Notification & Create PM09 Type Order Click Create button Selection of M6 Notification Go to T. Code IW28 Selection of Notification Flag check box Outstanding (as reqd) Enter Notification Date
of Order Tab Navigate> SAP Screen
116
| 10-Dec-13

Other Field automatically Populated. Select Relevant Work Center for Operator & Enter Number of Hours Go to Component TAB & Attach Required Material Navigate> SAP Screen Go to Operation TAB Select Relevant Work Center (Type 0001) Enter Number of Hours
Create PM09 Type Order Select Relevant Maintenance Activity Type( Always RVN)
117
| 10-Dec-13

GO to IW38 & Search PM09 Type Order
118
| 10-Dec-13

Navigate> SAP Screen Release Order & Issue Required Material. Carry out Repair Work As per Request
119
| 10-Dec-13

Further process of order will remain same as explained in process 1. Preventive Maintenance Navigate> SAP Screen
120
| 10-Dec-13
6. EXTERNAL REPAIR MAINTENANCE PROCESS

BASIC PROCESSES
BASIC STEPS OF EXTERNAL REPAIR MAINTENANCE PROCESS

5. Work shop Repair 6. External Repair/Services 7. Calibration
Creation of PM09 Type Order Selection PMEX Activity type Creation of Purchase Requisition Creation Of Purchase Order Confirmation of External Service Entry Sheet Technical Completion of Orders
121
| 10-Dec-13

BASIC STEPS OF EXTERNAL REPAIR PROCESSES
Creation of PM09 Type Repair Order Select Relevant Type Maintenance Activity (Always RVN, RWN) Go to Operation TAB
Creation of PM09 Type Order

Selection PMEX Activity type Creation of Purchase Requisition
Select Control Key As PMEX
Creation of Purchase Order

Enter Operation & Select It
Confirmation of External Service Entry Sheet Technical Completion of Orders
Click External Service Button POP Screen Will Appear Enter Material Group S 524,Purchase Group, Tracking Number Enter & GO to External Processing operation Screen
122
| 10-Dec-13

Write Short Text of External Service , Approximate Cost of Repair, Quantity & Unit Write Desired Vendor Code Enter Cost Element & click Pop Screen of Purchase request Will Appear Enter Department (i.e Main Planner group) Go back to Order main screen Release it & Save Order Go to Change Mode of Order & select TAB Actual Data You will get PR number Navigate> SAP Screen
Creation of PM09 Type Order Selection PMEX Activity type Creation of Purchase Requisition Creation of Purchase Order Confirmation of External Service Entry Sheet Technical Completion of Orders
123
| 10-Dec-13

Go To Change Mode of PR (ME52N)
GO To Document Overview & Select Relevant PR GO TO Customer TAB & Enter all Required Deatils Save PR Navigate> SAP Screen
Creation of PM09 Type Order Selection PMEX Activity type Creation of Purchase Requisition Creation of Purchase Order Confirmation of External Service Entry Sheet Technical Completion of Orders
124
| 10-Dec-13

MM Will Prepare Purchase Order on PR


125
| 10-Dec-13


MM Will Prepare Service Entry Sheet You will Accept Service Entry Sheet

126
| 10-Dec-13

This Type of Order to be TECO only When FINAL Service Sheet Made. Save


127
| 10-Dec-13
III. MANAGING REPORTS
128
| 10-Dec-13
STANDARD REPORTS
1. Object Class Statistics
[MCI1]
Object breakdown analysis in terms of Maintenance cost
Standard drill down (Key Figure)

Assembly Construction year Manufacturer Material Object class Month
129
| 10-Dec-13
STANDARD REPORTS
2. Manufacturer Analysis
[MCI2]
Object breakdown analysis in terms of Maintenance cost Manufacturer wise.

Assembly Construction year Manufacturer Material Object class Month
130
| 10-Dec-13
STANDARD REPORTS
3. Location Analysis
[MCI3]
Object breakdown analysis in terms of Maintenance cost Location wise

Assembly Equipment Functional Location Location Maintenance plant Planner group Planning plant Plant section Month
STANDARD REPORTS
4. Planner Group Analysis
[MCI4]
Object breakdown analysis in terms of Maintenance cost Planner Group wise Standard drill down (Key Figure)
Assembly Equipment Functional Location Location Maintenance plant Planner group Planning plant Plant section Month
132
| 10-Dec-13
STANDARD REPORTS
5. Single Object - Damage Analysis
[MCI5]
Object Damage analysis in terms of Damage & Causes, Notification Type wise Standard drill down (Key Figure)
Activity code Cause of damage CdGrp: damage cause Code group: activity Code group: damage Damage Equipment Functional Location Notification type Month
133
| 10-Dec-13
STANDARD REPORTS
6. Object Statistics
[MCI6]
This report provide the detail about the object statistics ( like how many Equipment installed on a Function Location)
Object class Manufacturer Material Construction year Month
134
| 10-Dec-13
STANDARD REPORTS
7. Breakdown Analysis
[MCI7]
This report provide the Breakdown Analysis information (No. of B/D, MTTR, MTBR etc.). Standard drill down (Key Figure)
Equipment Functional Location Object class Month
135
| 10-Dec-13
STANDARD REPORTS
8. Cost Analysis
[MCI8]
This report provide the Breakdown Analysis information ( No. of B/D, MTTR, MTBR etc.). Standard drill down (Key Figure)
Equipment Functional Location Object class Month
136
| 10-Dec-13
STANDARD REPORTS
9. MTTR/MTBR Equipment
This report provide :
[MCJB]
MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR etc.).

Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)
137
| 10-Dec-13
STANDARD REPORTS
10. MTTR/MTBR Functional Location [MCJC]

This report provide : MTTR/MTBR Analysis Equipment wise ( No. of B/D, MTTR, MTBR etc.)
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)
138
| 10-Dec-13
6.2 LIST OF DEVELOPED REPORTS
139
| 10-Dec-13
LIST OF DEVELOPED REPORTS:

No. following PLANT REPORTS S. The are the Reports that are being developed in SAP: 1 2 List of Damage & Cause - Summary Report (Equipment wise) Breakdown Matrix - Equipment ABC indicator & breakdown category wise
3
4 5 6 7 8 9 10
Work Center / Equipment wise Material Consumption

Equipment Schedule Maintenance Report Breakdown why-why Analysis Report PM order Skipped / Rescheduled Report PM Order Slippage Summary Report ( Schedule Maintenance Slippage in Plant VC) Preventive Maintenance Work Request Report Motor Failure Report Inspection Check List
140
| 10-Dec-13

S. No. 11 12 13 14 PLANT REPORTS Maintenance Order / Operation Pending List Section / Equipment Performance Report Equipment Lubrication Consumption Report Quarterly Lubrication Consumption Report
15
16 17 18 19
Purchase Request Tracking Report

Equipment Maintenance Cost Report List of Service Entry Sheets Work Center Wise Service Cost Report Shutdown (consolidated) Planning Report (resources & cost)
141
| 10-Dec-13

S.No. 20 21 22 23 24 25 26 27 MINES REPORTS Tyre Life Summary Report Equipment Position Wise Tyre Run Report Tyre Maintenance Register Oil Consumption Report Oil, Filter & Lubricant Monitoring Report Assembly Life Details Sub assembly Performance Report Breakdown Summary
142
| 10-Dec-13
143
| 10-Dec-13
CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1

Crete Measuring Point- IK01
Measuring Point Object
Select Equipment
Select Relevant Measuring Point Category
Flag
for Measuring Point as a Counter
Write Measuring Position Description
Write Description of Measuring Point Select From Drop Down ,Always use RUNNINGHOURS
Attach Relevant CHARACTERISTICS
144
| 10-Dec-13
CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2

Press Enter ICON
Enter Counter Over Flow Reading
Maximum Reading of Counter
Enter Annual Estimate Reading
It Will be drive Plan
Press ICON
For Save
Message : Measuring Point . Created
THE END
145
| 10-Dec-13
CREATION OF MESURING POINT (LUB/Diesel Consumption) Sheet 1/2

Select Equipment
Select from Drop Down Always Select Category L- for Lubrication & F- Fuel Consumption
Flag
for Measuring Point as a Counter
Write Description of Measuring Point Select From Drop Down , ,Always LUB CONCOSUMPTION..
146
| 10-Dec-13
CREATION OF MESURING POINT(LUB/Diesel Consumption) Sheet 2/2

Press Enter ICON
Dont Enter Counter Over Flow Reading & Annual Estimate Reading
Enter Save ICON Button
Message : Measuring Point ..Created
Press ICON
Message : Measuring Point ..Created The END

CREATION OF MESURING POINT Sheet 1/2

Select Equipment
Press Icon
Write Description of Measuring Point
Select From Drop Down
148
| 10-Dec-13
CREATION OF MESURING POINT Sheet 2/2

Press Enter ICON
Message : Measuring Point ..Created
Press ICON
Message : Measuring Point ..Created THE END

CREATION OF MESURING POINT DOCUMENT (IK11) Creation of Measuring Document IK11
Select Desired Measuring Point
Enter ICON Button for entering Reading
Next Screen will Appear Counter should be GREATER than Previous Reading or Difference not more than 24 Hours
Enter Counter Reading or Difference of Counter
Press ICON Button
For Save
Message : Measuring Document ..Created.
THE END
150
| 10-Dec-13
MAINTENANCE ITEM
Continued..
WITH TIME BASED PACKAGE
151
| 10-Dec-13
CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04

Create Maintenance Item IP04
Maintenance Plan Category
Select from Drop Down, Use Always GILDAY & GILMON Only
Write Maintenance Item Description
Enter Equipment
Write ORDER Type
This will be PM01 Always Select from Drop Down (Use PVM Or AMC )
Maintenance Activity Type
Attach Relevant Task List
152
| 10-Dec-13
CREATEING MAINTENANCE ITEM (TIME BASE) Sheet -2/2

For Selection of Task List Use Icon
Task List Display Screen will Appear on Screen
Flag
General Task List
Press Icon , Lists
Screen will appear with List of Task
Select Appropriate Task List
Press Icon Enter
Press Icon
for Save
You will get Message : Maintenance Item ( System Generated Number) Created. THE END
MAINTENANCE ITEM
WITH PERFORMANCE BASED PACKAGE
154
| 10-Dec-13
CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2

Create Maintenance Item IP04
Maintenance Plan Category
Select from Drop Down ALWAYS Use PERFHR For Plant,TPP,DG Equipment & MINHR For Mines Equipment
Write Maintenance Item Description
Enter Equipment
Write ORDER Type
This will be PM01 Always
Maintenance Activity Type
Attach Relevant Task List
155
| 10-Dec-13
CREATE MAINTENANCE ITEM (PERFORMANCE BASE )Sheet -2/2

For Selection of Task List Use Button
Task List Display Screen will Appear on Screen
Flag
General Task List
Press Button ,
Screen will appear with Task List
Select Appropriate Task List
Press Icon
Press Icon
for Save
You will get Message : Maintenance Item ( System Generated Number) Created THE END
Creation of Maintenance Item-[IP04]
157
| 10-Dec-13
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3 Create Maintenance Plan (IP01)
IP01
Maintenance Plan Number is System Generated Number
Maintenance Category Select from Drop Down ,Always Use GILDAY & GILMON
Press Icon
Write Maintenance Plan Short Description
Go to TAB
For Assigning Maintenance Item
POP Screen will appear Message : Possible Deletion of Data Entered When Selecting
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 2/3 Display Maintenance Item :Selection Criteria Screen Will Appear ,Write Equipment Number & Press Icon
Main Planner Group ,Main Work Center & other field automatically Populated from Equipment Master
Main Planner Group ,Main Work Center & other field automatically Populated
Press Icon
Go to TAB Maintenance Plan Scheduling Parameter
Write Scheduling Period :365 Days
Flag
Fro Completion Requirement
159
| 10-Dec-13
CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 3/3
Press Icon
For Save
Pop Screen Will Appear For START DATE
Select Radio Button NO
Press Icon
Message will Appear on Screen : Maintenance Plan .Created
The End
160
| 10-Dec-13
CREATION OF MAINTENANCE PLAN (PERFORMANCE BASE) Sheet 1/3 Create Maintenance Plan (IP01)
Maintenance Plan Number is System Generated Number
Maintenance Category
Select from Drop Down ,Always Select PERFHR For Plant, DG, TPP & MINHR For Mines
Press Icon
Write Maintenance Plan Short Description & Enter Counter
Go to TAB
For Assigning Maintenance Item
POP Screen will appear Message : Possible Deletion of Data Entered When Selecting
CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 2/3 Display Maintenance Item :Selection Criteria Screen Will Appear ,Write Equipment Number & Press Icon
Main Planner Group ,Main Work Center & other field automatically Populated
Press Icon
Go to TAB Maintenance Plan Scheduling Parameter
Write Scheduling Period :365 Days
Flag
For Completion Requirement
162
| 10-Dec-13
CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 3/3
Press Icon
For Save
Pop Screen Will Appear For START Counter Reading
Select Radio Button NO
Press Icon
Message will Appear on Screen : Maintenance Plan .Created
The End
163
| 10-Dec-13

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PLANT MAINTENANCE SYSTEM

Presentation Title | Confidential | Document ID

PLANT MAINTENANCE SYSTEM

I. MANAGING MASTERS II. MANAGING MAINTENANCE PROCESSES III. MANAGING REPORTS

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

1. Functional Locations 2. Equipment Master 3. Class & characteristics

Presentation Title | Confidential | Document ID

Function Location Category

Presentation Title | Confidential | Document ID

FUNCTIONAL LOCATION STRUCTURE

Presentation Title | Confidential | Document ID

FUNCTION LOCATION STRUCTURE

Edit Mask AAA AANN AAX AAX XXX XXXX

Code GIL RC01 RC1 CM1 FEG

Presentation Title | Confidential | Document ID

1. Functional Locations 2. Equipment Master 3. Class & characteristics

Presentation Title | Confidential | Document ID

FUNCTION LOCATION CATEGORY

Presentation Title | Confidential | Document ID

NAVIGATE > SAP SCREEN

Presentation Title | Confidential | Document ID

1. Functional Locations 2. Equipment Master 3. Class & characteristics

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

PRODUCTION RESOURCES/TOOLS TPP/DG EQUIPMENTS UTILITY EQUIPMENTS

Presentation Title | Confidential | Document ID

EQUIPMENTS CATEGORY & NUMBER RANGE

Presentation Title | Confidential | Document ID

TECHNICAL OBJECT TYPE

Technical Object Types are the logical grouping of Objects on the

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

MAIN WORK CENTER

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

COST CENTER/ INTERNAL ORDERS

Presentation Title | Confidential | Document ID

NAVIGATE > SAP SCREEN

Presentation Title | Confidential | Document ID

1. Functional Locations 2. Equipment Master 3. Class & characteristics

Class Type Class Group Characteristics Group

Unit of Measure for

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

Presentation Title | Confidential | Document ID

CLASS AND CHARACTERISTICS GROUPS CODES

Char. Group Code Description

Presentation Title | Confidential | Document ID

NAVIGATE > SAP SCREEN

Display of Class List [CL03]

Presentation Title | Confidential | Document ID

1. Functional Locations 2. Equipment Master 3. Class & characteristics

Presentation Title | Confidential | Document ID

The Parameter driving / governing Equipment performance/Output is

Presentation Title | Confidential | Document ID

NAVIGATE > SAP SCREEN

Find out The Maintenance Inspection Characteristics prepared-[QS24]