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Plant Maintenance

The goal of this session is to give you an introduction to

and a basic understanding of:
SAP PM philosophy
SAP PM terminology
SAP PM screens

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SAP R/3 Plant Maintenance

Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis

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Background Philosophy

Business can not afford to have plant idle

Business can not afford to have plant running inefficiently
Business demands a consistently high quality of product
from plant
Legal, Safety and Environmental issues demand a clean
efficient plant

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SAP Plant Maintenance

Solutions for management and maintenance of technical

systems
Maintenance incorporates:
Inspection: determine the actual condition
Maintenance: maintain the ideal condition
Repair: restore the ideal condition
Construction and modification

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Scope of PM Activities

Management of operational systems and technical

resources
Regular activities scheduled via Maintenance plans
Malfunctions entered as notifications & passed to planning
Maintenance Orders for work required
type of activity, task steps, & resources
Completed Orders = task related, function and object
oriented history

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Functionality
Can fulfil all day-to-day processing requirements of Plant
Maintenance
Experience and suggestions of varied customers used in
development
Fully integrated with other modules
Materials Management
Purchasing
Inventory Management
Financial Accounting

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Functional Overview

Plant Maintenance (PM)

- Technical Objects
- Work centers
- Main. task lists
- Maintenance planning
- PM Processing
- Capacity planning
- Information system

SD

CO

MM

R/3

PP

AM

Client / Server
PS

ABAP/4

QA

OC

PM
HR

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FI

IS

Different (Major) Maintenance

Types
System generated Work Orders
Time dependent

Manual Intervention
Notifications or
Directly created Work Orders

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SAP R/3 Plant Maintenance

Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis

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Plant Maintenance, a lot of terms

PM Order

Work Center
Maintenance Plan

Maintenance Strategy
Maintenance Item

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Structuring
Reduces recording and management effort

Simplifies processing

Enables better planning and evaluation

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Structuring
Functional: location or process oriented using hierarchies

Object related: description of every piece of equipment

Technical: allocate objects to different classes

Accounting: allocate objects to cost centres or assets

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Functional Location
Definition:
an element in a technical structure,
representing an area of a system where an
object can be installed / maintained
Functional
Location

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Reasons for:
Need to represent system
according to function
PM tasks are planned / executed for
individual areas
Records are kept per individual area
Costs are followed per individual
area

Functional Location Structure

San Jose

Production

Test

...

Process

LINE 1

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LINE 2

LINE 3

Functional Location Structure

Structure Indicator: ABC1
Edit Mask:
XXXX-XXX-XX-XXX-XXX-XXX
Hier. Levels:
1
2 3
4
5
6
FUNCTIONAL LOCATION

DESCRIPTION

PL01

San Jose

PL01-PRD
PL01-PRD-PR
PL01-PRD-PR-LN1
PL01-PRD-PR-LN2
PL01-PRD-PR-LN3

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Production
Process
Line 1
Line 2
Line 3

Functional Location
Structure Indicator
To describe the number structure of Functional Locations
To define the hierarchy levels
To describe all similar functional locations in the same way
A strict top down definition

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Create Functional Location

Structure Indicator
Menu Path:
Tools - Customizing - Configuration - Logistics - Plant
Maintenance - Master Data - Technical Objects - Functional
Location - StructIndicator

1. Display:

PL01

2. Create:

Structure Indicator, ABCX (AAA-XXXX-XX)

3. Exercise (1):

See Participant hand out (Struct. Indicator)

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Functional Location Structure

San Jose

PL01

PL01-PRD

Production

Test

LINE 1

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PL01-PRD-PR

Process

...

San Jose

LINE 2

LINE 3

PL01-PRD-PR-LN1
PL01-PRD-PR-LN2
PL01-PRD-PR-LN3

Production

Process

Line 1
Line 2
Line 3

Create Functional Location

Menu path:
Logistics - Plant Maintenance - Technical Objects Functional Location

1. Display:

Functional Location PL01

2. Create:

Functional Location, usage of TRW (2 levels)

3. Exercise (2):Functional Location

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Equipment
Equipment

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Definition:
An individual, physical object
which is to be maintained
independently

Equipment data

General data
Location data
PM data
Sales and distribution data
Multi lingual texts
Link to documents ( drawings, ref. manuals etc)
Link to functional location

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Create Equipment

Menu Path:
Logistics - Plant Maintenance - Technical Objects Equipment

1. Display:

Equipment PT316

2. Create:

Equipment TD100

3. Exercise (3):

Equipment

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Object Link
Definition
a relationship between 2 technical systems (functional
location or equipment) horizontally

Use
To be able to analyse the impact on other systems when
another has malfunctions / planned maintenance

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Object Link, characteristics

Different types:
Pump A

Pump B

One-Way Link

Host A

Host B

Two-Way Link

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Object Link

Menu path:
Logistics - Plant Maintenance - Technical Objects Equipment OR Functional Location - Object Link

1. Display:

Object Links #: 10000001

2. Create:

Object Links: PT316 and 15-PU-15A

3. Exercise (4):

Object Links

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Material Master views

Purchasing

Engineering

Accounting

Forecasting

Material
Master
record

Inventory

MRP
Sales

The Material Master Record is a central data object in the SAP system.

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Equipment Bill of Material

Definition:
a complete formally structured list representing all parts, material, documents
required to maintain an equipment
Equipment

Equipment

15-PU-15A

Spares

Spare

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Spare

Spare

Equipment Bill of Materials

Equipment
level 0
Equipment

Assembly
Assembly

Spare

Assembly

level 1

Spares
Spare

Spare

level 2

Assembly

Spare

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Spare

Spare

Equipment Bill of Materials

15-PU-15 A
5014-0042
5014-0043
5021-0031
7501-0459
7501-0532
1700-0014
1700-0015
1700-0023
1700-0028
etc.

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LUBRICATION PUMP
BEARINGS RHP.NH314
BEARINGS SKF.Q1314MA
BEARINGS RHP.N221 ECP
SEALS OIL 90 x 130 x 12
SEALS OIL 110 x 130 x 12
PUMP SHAFT 304L
PUMP IMPELLOR 304L
RINGS WEAR CASING POS NO 9-9/1
GASKET SETS

Create Equipment Bill of Materials

Menu path:
Logistics - Plant Maintenance - Technical Objects - BOM Equipment BOM

1. Display:

Equip. BOM PT316 or 15-PU-15Al

2. Create:

Equip. BOM TD100

3. Exercise (5):

Equipment Bill 0f Materials

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Elements in System Structuring

Functional
Location

Installation of one or more pieces of equipment at a

functional location

Equipment

Installed equipment

Assembly

Spares

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Equipment Bill of Materials

Assembly (material)
Bill of Materials

Install Equipment

Menu path:
Logistics - Plant Maintenance - Technical Objects Functional Location

1. Display:

Install Equipment PT316 (SLK-CR300-A1)

2. Create:

Install Equipment TD100 on BRU-level

3. Exercise (6):

Install Equipment

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Work Centers
A work center defines where an operation can be executed
(a machine or a group of machines ), or who is to carry out
an operation ( a person or a group of people).

In the work center you can calculate costs, capacities and

dates for the operations.

Work centers can be structured hierarchically. In this way

required and available capacity can be cumulated

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Work center, characteristics

Work center
Default
values

Task List

Costing
data

Scheduling
data and
available
capacity

Costing

Lead time
Scheduling
Capacity planning

2724,00
1200,00
124,00
4048,00

100

80

60

40

20

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Create Work Center

Menu path:
Logistics - Plant Maintenance - Work Centers - Work Center

1. Display:

Work Center, PMWC100

2. Create:

Work Center, PMWC500

3. Exercise (7):

Work Center

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Material
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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SAP R/3 Plant Maintenance

Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Task List

What work has to be done ?

Who is to do the work ?

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Task List
Work to be done

Resource

Disconnect Motor
Make a scaffold
Remove insulation
Replace A with B
Replace insulation
Connect Motor
Test

Electrical Department
External contract
External contract
Mechanical Workshop
External contract
Electrical Department
NA Mechanical Dept.

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Maintenance Task List

Definition:
a sequence of individual maintenance activities which must
be performed in order to fulfill a certain maintenance
requirement

Characteristics:
can be defined for a particular equipment or as a general list
multiple alternatives per task list
sequence of operations per task list
only one capacity requirement per operation
required material per operation

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Maintenance Task List

Material Allocation

Task List

operation 1

operation 2

operation 3

1 x Item A

2 x Item B

1 x Item C

Equipment

Equipment
Bill of Materials

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operation 4

Create Maintenance
Task List
Menu path:
Logistics - Plant Maintenance - Maintenance Task Lists Maintenance Task Lists - Equipment task lists

1. Display:

Maintenance Task Lists, PT316

2. Create:

Maintenance Task Lists, TD100

3. Exercise (8):

Maintenance Task Lists

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Maintenance Strategy

15
When are jobs to be performed ?
Yearly ?
Monthly ?
Weekly ?

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Maintenance Strategy
Definition:
a schedule of planned maintenance activities which should
take place at predefined intervals

Characteristics:
Independent of any equipment or functional location
schedule by either calendar or key-date
rules for early and late confirmation
variable number of maintenance packages
package has description, frequency and priority

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Maintenance Strategy

Example

Maintenance of pressurized
container
Package 1:
weekly routine check
Package 2:
monthly pressure check
Package 3:
yearly overhaul

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Display Maintenance Strategy

Menu path:
Logistics - Plant Maintenance - Maintenance planning Maintenance strategy

1. Display:

Maintenance Strategies, ST001

2. Exercise (9):

Maintenance Strategies

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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How to combine

Functional location
Equipment
Maintenance task list
What work has to be done ?
Who is to do the work ?

Maintenance strategy
When are jobs to be performed ?

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Usage of a Maintenance item

A maintenance item describes the activities to be carried

out on an object and their frequency

Note:
A Maintenance item IS NOT an Equipment (e.g. installation)

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Maintenance Item
Maintenance Item
Object List
Strategy
Primary Object
Location/account
assignment

Equipment #
Funct. locations
Task List
Operations

Description

The maintenance item describes the type of maintenance or inspection

activity to be carried out on a object (using short and long texts).

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Maintenance item
Due Dates

Activities

Maintenance strategy
Maintenance package

Task list
with operations

Maintenance Item
Maintenance objects with
tasks to be carried out
Maintenance Plan
Dates
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Create Maintenance item

Menupath:
Logistics - Plant Maintenance - Maintenance planning Maintenance Items

1. Display:

Maintenance Items, SLK-MP-03

2. Create:

Maintenance Items, TD100 (MI-SLK-TD01)

3. Exercise (10): Maintenance Items

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Maintenance Plan
Due Dates

Activities

Maintenance strategy
Maintenance package

Task list
with operations

Combination of
Maintenance
Strategies and
Task Lists

Maintenance Item
Maintenance objects with
tasks to be carried out
Maintenance Plan
Dates

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System generates
Work Orders based
on planned dates

Maintenance Plan

Describes dates and scope of the maintenance activities to

be performed

Characteristics:
combination of maintenance items
all items selected must have the same strategy
includes the cycle start date
basis for scheduling maintenance orders

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Maintenance Plan
Scheduling

The following data is used to automatically schedule

maintenance orders:
The start date and last completion confirmation from
the plan
opening period (% of cycle time)
shift factors (early / late confirmation) (Slide)
tolerances (based on smallest interval)
call interval (actual length of scheduling period)
the cycles and the task list from the item
the packages from the strategy

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Maintenance plan,
shift factors example
Planned
date

Confirmed
on

Next date
planned

Shift
factor

01.08.99

16.08.99

01.09.99
16.09.99
08.09.99

0%
100%
50%

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Maintenance plan, call status

Other possible
stati are:

When a maintenance
plan is scheduled all
orders get the status ON
HOLD

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Elements in Maintenance Planning

Maintenance Strategy
Maintenance
Strategy

Maintenance
packages:
time-dependent
activity-based

Maintenance Plan

Maintenance Call

Maintenance
Schedule

Schedule
forecast

Maintenance
Orders

Maintenance
Item

Objects
Funct. locations
Equipments

Task lists

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Create Maintenance plan

Menu path:
Logistics - Plant Maintenance - Maintenance planning Maintenance Plans

1. Display:

Maintenance Plans, MP-SLK-DEMO

2. Create:

Maintenance Plans, use MI-SLK-TD01

3. Exercise (11): Maintenance Plans

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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SAP R/3 Plant Maintenance

Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis

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Maintenance Order

PM planning

PM Notifications

PM Orders

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Direct order
creation

Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Notifications
Definition:
A document which holds all data which is needed to trigger an unplanned
maintenance activity or data on an activity performed already

Result from unplanned, reported

exceptions
Allow for planning of resources
Not used in critical situations, when
Order is entered directly

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Notification Types
Malfunction report:
Describes a malfunction, which normally affects the availability of
and object and leads to a maintenance order.
Activity report:
Describes a maintenance activity which has already been carried
out, not necessarily due to malfunction. For documentation
purposes.
Maintenance request:
A request for the maintenance department to carry out an activity
not based on malfunction.

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Notification Structure

NOTIFICATION HEADER

Date/Time/Reported by
Description
PM Object: Functional
location
Equipment
Assembly

NOTIFICATION TASKS

Dates
Task Description

NOTIFICATION ITEMS

ACTIVITIES

Damage location
Damage
Cause of Damage

Activity
Execution factors

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Create Notification

Menu path:
Logistics - Plant Maintenance - PM Processing - Notifications
Maintenance Notifications, 10000040, PT316
1. Display:
Maintenance Notifications, TD100
2. Create:
3. Exercise (12): Maintenance Notifications

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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Maintenance Order

Definition:

PM Orders

A document used to:

plan the execution,
monitor the progress of maintenance activities in
detail
to collect all costs accrued during execution.

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Maintenance Order Creation

Based on one or more existing notifications

Created automatically based on a maintenance plan
Entered manually

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Functional Procedures
PM Organization
Plants

Direct order
creation

PM planning

PM Requirements/
notifications

Planners
PM Orders
Workshops

Capacities

Material

Internal services

External services

PM Objects
Functional
Location
Completion confirmations
Equipment

Assembly

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PM History
Downtimes, problems
Costs, Measures

PM Order Structure
HEADER

number, description, date, type, priority

LOCATION and
ACCOUNTING
OBJECT

physical location, suggested account assignment

functional locations, equipment, assemblies, notifications

SETTLEMENT

planned/actual costs, final account assignment

OPERATION

description of work to be done, scheduling data

COMPONENT

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materials needed for work

PM Order Integration

Order Costs maintained throughout the cycle (Finance)

Reservations for planned materials (MM - inventory)

Requisitions for non-stock items or services (MM purchasing)

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Order Costing
PM ORDER
Internal processing
Op. 10 ME 3 hrs
Op. 20 EL 1 hr
External processing
Op. 30 EXT 1 hr
Stock material
2 pcs material ABC
Non-Stock material
2 pcs material XYZ

COSTS
Internal
Processing

500

External
Processing

150

Stock
Material

300

Non-stock
Material
Total

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500
-------1450

Maintenance Processing
for Unplanned Tasks
Malfunction, error
request, activity

Requesting
a task

2
PM NOTIFICATION
What
When
Where
--------------------------Techncal
information
Breakdown

Create the order

Planning the task
Who
When, for how long
What steps
Resources

7
Completion

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Execution
material issue
procuring PRTs
worksteps

Releasing
the order

Technical information
Breakdown
Causes
Objects affected
Activities

PM History

Maintenance Processing
for Unplanned Tasks
1. Reporting a malfunction or a defect in a system or part thereof (ie
describing the condition of the system
2. requesting a maintenance task
3. creating a maintenance order and planning the task
4. releasing the maintenance order
5. executing the order
6. completing the task and confirming completion of order
7. entering technical information such as findings, cause, downtime,
activities
8. completing the order and the notification, storing relevant data for
evaluations, and for planning future maintenance activities

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Maintenance Order Status

CRTD : after creation
REL(R) : released (rejected) - papers can be printed, time recorded
and material issued
PRC : pre-costed (standard costs have been calculated)
(P)CNF : (partly) confirmed - time used has been recorded
MSPT : missing parts
TECO : technical completion

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Create Maintenance Order

Menu path:
Logistics - Plant Maintenance - PM Processing - Orders

Maintenance Orders, 900098

1. Display:
Maintenance Orders, with reference to 10000040
2. Create:
3. Exercise (13): Maintenance Orders

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Structuring of Data
Functional Location
Structure Indicator
Equipment
Object Link
Material Master
Equipment Bill of Materials
Work Center
Maintenance Task List
Maintenance Strategy
Maintenance Item
Maintenance Plan
Notifications
PM order

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SAP R/3 Plant Maintenance

Agenda
Introduction
Structures and Master Data
System generated Maintenance
Manual Intervention
History/Analysis

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Maintenance History

Usage
History

Master
records
Functional
Equipment
Location

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Order
History

PM Order
Costs
Materials
Operations

Notification
History

PM
Notification

View Maintenance History

and analysis

Menu path:
Logistics - Plant Maintenance - PM Processing - History - Notification List Display
Logistics - Plant Maintenance - PM information system - Standard
Analyses - Manufacturer - Display
Exercise (14):

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History and PM information system

Plant Maintenance Process

Summarized
You should be able to
Create a Functional location (structure)
Create and install an equipment
Create a maintenance plan
Create notifications
PM order handling

Exercise 15

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Plant Maintenance Process