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Main Business Scenario

 SAP PM performs the following types


of maintenance
 Breakdown Maintenance
 Corrective Maintenance

 Refurbishment of Spare Parts

 Preventive Maintenance

 Project-Oriented Maintenance

 SAP AG 1999
Types of Maintenance

Tool Cleaning
assembly DIN 31051

Inspection Preventive
maintenance
To
Modification determine the To Refurbishment
actual condition of maintain the
an object target condition
of an object

Repair

To restore the
target condition Production
of an object
Construction assistance

........
 SAP AG 1999
Plant Maintenance Integration

Materials Management
Production Joint Venture

Controlling
Project Management

Financial Accounting
Plant Maintenance
HR System

Investment Management Funds Management

Asset Accounting
Real Estate Management

 SAP AG 1999
Plant Maintenance Process Overview

Organizational levels A Maint. Plants / Planning plants / Work centers

Technical Objects B Identification / Structuring / Classification

Breakdown Maintenance C Malfunction reports / Malfunction order

Corrective Maintenance D Internal-/External Service / Material

Refurbishment of Spare Parts E Material with separate valuation

Preventive Maintenance F Work scheduling / Maintenance planning

Project-Oriented Maintenance G Maint. Projects / Shutdowns / Investments

Work Clearance Management H Work clearance application / Work clearance doc.

Analyses and Reports I Standard analyses / Flexible analyses / BW

 SAP AG 1999
Organizational Structures in Plant Maintenance

General Organizational Units in Logistics

Client Company code

Plant

Location-Based Organizational Units

Maintenance plant For example, site,


Location building,

Maintenance Work For example, mechanics


Centers

Planning-Based Organizational Units

Maintenance planning plant


Maintenance planner For example, foreman,
groups work scheduling

 SAP AG 1999
Maintenance Work Centers

Maintenance Work Centers


For example:
Welding
Metalworking
Mechanics

 SAP AG 1999
Technical Objects

Contents:

 Functional locations
 Equipment
 Bills of material

 SAP AG 1999
Technical Objects: Process

Technical Objects B Identification / Structuring / Classification

1 Identification
Which objects are relevant Maintenance
to Plant Maintenance? engineer

2 Structuring
Which objects are Maintenance
mapped? engineer

3 Classification
Which object classes
with which technical data?
Maintenance
engineer

 SAP AG 1999
Example of Functional Location Structure

C1
Clarification
plant
C1-M C1-B
Mechanical Biological
cleaning cleaning

C1-M01 C1-M02 C1-B01 C1-B02


Oil/fat Pump Filtering
Sand trap trap plant station

C1-M01-1 C1-M01-2 C1-M01-3 C1-M02-1 C1-M02-2 C1-M02-3 C1-B01-1 C1-B01-2 C1-B02-1 C1-B02-2
Sand Fat Filtering
Reservoir Ventilator dredger Reservoir Ventilator dredger Pump 1 Pump 2 Ventilator cell

C1-B02-1A C1-B02-1B C1-B02-2A C1-B02-2B C1-B02-2C


Filtrate
Valve 1 Valve 2 Inlet level Outlet

C1-B02-2A/1 C1-B02-2A/2 C1-B02-2C/1 C1-B02-2C/2


Valve 1 Valve 2 Valve 1 Valve 2

 SAP AG 1999
Equipment

Individual physical object to be


maintained as an autonomous unit

Means of production

Means of transport

Test equipment

Equipment Production resources/tools

Customer devices

Buildings, property

Systems, system parts

Vehicles & Aircrafts

 SAP AG 1999
Criteria for Equipment Master Record

For what purpose is a piece of equipment created?

 Management of individual data

 Recording of maintenance tasks

 Object-based recording of costs

 Evaluation of technical data

 Recording of usage times

 SAP AG 1999
Installation/Dismantling of Equipment

 SAP AG 1999
Equipment Usage List

S-15

Usage List

03/01/ – 09/20/2000 S-15

 SAP AG 1999
Bills of Material in Plant Maintenance

Structuring
of object

Spare parts planning


in order

Maintenance bill of material Technical object

Spare parts planning


in task list

 SAP AG 1999
Possible Process Flow for Breakdown Maintenance

Production Maintenance planner


Order
Order
Call / create and
message release

0010 Check pump


0020 Renew seals

Technician Maintenance supervisor


Malfunction:
correct/ Order
confirm complete

 SAP AG 1999
Time Confirmations

Initial screen Individual entry


Collective entry
Collective entry using operation list
Overall Completion Confirmation

Scope Partial confirmation


Final confirmation

Reversal option

 SAP AG 1999
Corrective Maintenance: Process

Corrective Maintenance D Internal-/External Service / Material

1 Notification •Technical object •Date


•Description •Malfunction:
Maintenance
planner
2 •Work to be performed •Material
Planning •Internal/external resources •Tools

3 •Order release •Capacity leveling


Scheduling •Printout •Availability check

Technician/
4 Execution •Planned/unplanned mat. withdrawal Storeperson

5 •Time conf. •Order settlement Maintenance


Completion •Tech. completion •Technical confirmation supervisor

History
Material usage, orders, notifications, PMIS, usage list

 SAP AG 1999
Cycle for Corrective Maintenance

Corrective Maintenance D Internal-/External Service / Material

1 Notification
Technical object
Description
Due date
Malfunction
Production worker
Maintenance planner

Work to be performed Material


2 Planning Internal/external resources

Order release Capacity leveling


3 Scheduling Printout Availability check

4 Execution
Planned/unplanned material withdrawal
External procurement

5 Completion
Time confirmation
Tech. Completion Tech. confirmation

History
Material usage, orders, notifications, PMIS, usage list

 SAP AG 1999
Cycle for Corrective Maintenance

Corrective Maintenance D Internal-/External Service / Material

1 Technical object Due date Production worker


Notification Description Malfunction Maintenance planner

2 Planning
Work to be performed Material Maintenance
Internal/external resources planner

3 Scheduling Order release Capacity leveling


Printout Availability check

4 Execution Planned/unplanned material withdrawal


External procurement

5 completion Time confirmation


Tech. completion Tech. confirmation

History
Material usage, orders, notifications, PMIS, usage list

 SAP AG 1999
Planning Alternatives: Internal or External Processing?

Internal processing External processing

 SAP AG 1999
Operations

List of operations

Operation Work center Control key Description ...

0010 Unit PM01 Oil change

0020 ME-1 PM01 Drain oil

0030 ME-1 PM01 Change oil filter

0040 ME-1 PM01 Add new oil

0050 EL-1 PM01 Renew electrics

0060 EL-1 PM01 Change battery

0070 EL-1 PM01 Check cables

0080 EL-3 PM01 Replace lights

 SAP AG 1999
Stock Material - Process Flow

Component
assignment

Material
reservation

Availability Order
check release

Printing
Automatic
availability
check
Goods
issue
 SAP AG 1999
Non-Stock Material – Process Flow

Component
Assignment

Purchase
application

Purchase order

Order
Release

Goods receipt

Company

Invoice Invoice
receipt
 SAP AG 1999
Cycle for Corrective Maintenance

Corrective Maintenance D Internal-/External Service / Material

1 Technical object Due date Production worker


Notification Description Malfunction Maintenance planner

2 Planning
Work to be performed Material Maintenance
Internal/external resources planner

3 Scheduling
Order release Capacity leveling Maintenance
Printout Availability check supervisor

4 Execution
Planned/unplanned mat.l withdrawal
External procurement

5 Completion
Time confirmation
Tech. completion Tech. confirmation

History
Material usage, orders, notifications, PMIS, usage list

 SAP AG 1999
Material Availability List

Traffic Light: Signifies:


All materials available for planned date
Green

Material available by latest date

Yellow

Material not available


Red

Goods receipt indicators:


Complete goods receipt

Goods receipt not made or incomplete

 SAP AG 1999
Cycle for Corrective Maintenance

Corrective Maintenance D Internal-/External Service / Material

1 Technical object Due date Production worker


Notification Description Malfunction Maintenance planner

2 Planning
Work to be performed Material Maintenance
Internal/external resources planner

3 Scheduling
Order release Capacity leveling Maintenance
Printout Availability check supervisor

4 Execution
Planned/unplanned mat. withdrawal Technician
External procurement Senior storeperson

5 Completion
Time confirmation Order settlement
Tech. Completion Tech. Confirmation

History
Material usage, orders, notifications, PMIS, usage list

 SAP AG 1999
Cycle for Corrective Maintenance

Corrective Maintenance D Internal-/External Service / Material

1 Technical object Due date Production worker


Notification Description Malfunction Maintenance planner

2 Planning
Work to be performed Material
Maintenance planner
Internal/external resources

3 Scheduling
Order release Capacity levelingMaintenance
Printout Availability check supervisor

4 Execution
Planned/unplanned mat. withdrawal Technician
External procurement Senior storeperson

Technician
5 Completion
Time confirmation, Tech. Confirmation
Maintenance
Tech. completion
supervisor

History
Material usage, orders, notifications, PMIS, usage list

 SAP AG 1999
Maintenance Order: Technical Completion (1)

Order 901760 Object list 901760

Technical completion
Reference date: Notification 10000123
Reference time:
Notifications: X
Notification 10000124

 SAP AG 1999
Action Log

Who changed what and when?

Maintenance
Causes of damage order
Address

Texts Maintenance
notification Purchasing data
Malfunction data
Sales data
Technical objects
Priorities
Account assignment data
Dates
Damage

 SAP AG 1999
Document Flow

All document types created


for the maintenance order
can be displayed:
Maintenance Notification
order
- Completion confirmation
- Goods movement
- Purchase requisition
- Purchase order

 SAP AG 1999
How is an External Service Processed?

Corrective Maintenance D Internal-/External Service / Material

Control key PM01


External service = " "
External company Service = " "
Work center Required Available Free
Capacity load

Control key
PM02 Purchase
Individual External service = X requisition
Service = " "
Purchase order

Control key Purchase


PM03 requisition Service
Service External service = X items
Service = X
Item

 SAP AG 1999
External Work Center: Process

Corrective Maintenance D Internal-/External Service / Material

1 Plan order with external


Maintenance
Order work center in operation
planner

2 Completion Time confirmation credited


Maintenance
external firm cost center
confirmation supervisor

3 Technical Technically complete the order


Maintenance
supervisor
Completion

4 Invoice
Invoice debit external firm Invoice verification
cost center clerk

 SAP AG 1999
Settling a Maintenance Order

AM asset
CO / PP / PM order
Project
Sender cost center 4350 Receiver cost center
Credit Debit
Settle activity Settled activity
TO 901956 10 h € 320
10 h € 320

Maintenance order 901956


Debit Settlement
Activity Settled activity
COST 4050 10 h € 320
10 h € 320

 SAP AG 1999
Individual Purchase: Process

Corrective Maintenance D Internal-/External Service / Material

1 Plan order Maintenance


Order Automatic purchase requisition planner

2
Purchase order Create purchase order Purchaser

3 Goods receipt
Book goods receipt Maintenance
(and enter service) supervisor

4 Technical Technically complete the order


Maintenance
supervisor
Completion

5 Invoice Invoice
Invoice verification
clerk

 SAP AG 1999
Service Procurement: Process

Corrective Maintenance D Internal-/External Service / Material

1 Plan order Maintenance


Order Automatic purchase requisition planner

2
Purchase order Create purchase order Purchaser

3 Service Service entry for Maintenance


Purchase order supervisor
entry

4 Technical Technically complete the order


Maintenance
supervisor
Completion

5 Invoice Invoice
Invoice verification
clerk

 SAP AG 1999
Cost Update in Order

Order 901760
Acceptance
Acceptance
document
posted !

0010 PM03 Lay steel pipe


Actual costs

 SAP AG 1999
Refurbishment of Spare Parts: Process

Refurbishment of Spare Parts E Material with separate valuation

1 Initiate Defective material in stock Maintenance


Refurbishment with condition-based value engineer

2 Maintenance
Order Create refurbishment order
planner

3 Material Remove defective material


Maintenance
withdrawal technician

4 Refurbishment Carry out refurbishment


Maintenance
technician

5 Return
Return refurbished material to Senior
storage storeperson

 SAP AG 1999
Condition-Based Material Valuation

Material
with valuation category C
(condition-based
valuation)

Valuation type Valuation type Valuation type


C1 C2 C3
€ 1,500.– € 1,250. – € 100. –

 SAP AG 1999
Refurbishment Order

Must be declared as
refurbishment order in
Customizing

Maintenance order 800175


Order type PM04

Material P-2001 Normal suction pump

Quantity 3
From C3 Quantity of parts to
To C2 be refurbished

Actual condition before refurbishment


Target condition after refurbishment

 SAP AG 1999
Types of Preventive Maintenance

Preventive
Maintenance

Time-based Performance-based Condition-based


2002
30 40 50
20 60
10 70
80
Printi
ng
Temperature Printing

Thickness

 SAP AG 1999
Preventive Maintenance: Process

Preventive Maintenance F Work scheduling / Maintenance planning

1 Task list
Create task lists for different
objects
Maintenance
planner

2 Maintenance Create maintenance plans


Maintenance
plan planner

Maintenance
3 Schedule Schedule Maintenance Plans
planner

Maintenance Maintenance
4 order
Process maintenance orders
technician

Technical Technically complete


Maintenance
5 Completion
Complete
supervisor
maintenance orders

 SAP AG 1999
Task list

Operations

Maintenance Work Centers

Material components

Production resources/tools

Maintenance packages

For planned maintenance


(preventive maintenance and inspection)
For routine maintenance
(planned repairs)

 SAP AG 1999
Single Cycle Plan: Business Process

2000 96 98

00
2002
2002

Inspection of
I must perform the "Portable fire extinguishers"
same inspections at
regular intervals.

 SAP AG 1999
Using a Task List to Include an Operation List

Maintenance plan
Task list

Scheduling data

0010 Switch off


Maintenance item
0020 Safety check
0030 External visual check

0040 Change seal

0050 Exchange H9 casing


0060 Check Z7 wire

 SAP AG 1999
Strategy Plan: Business Process

External visual inspection

Internal visual inspection

Check gear teeth for wear

Which parts must be


maintained at which
intervals?

 SAP AG 1999
Maintenance strategy

2001

Scheduling indicator Package definition

Time - factory calendar

3 months 6 months 9 months

Strategy

 SAP AG 1999
Project-Oriented Maintenance: Process

Project-Oriented Maintenance G Maintenance projects / Shutdowns / Investments

1 Plan
Create project or use existing
Project planner
project

2 Assign Create and assign orders


Maintenance
planner

3 Execute Execute orders Technician

4 Monitor Monitor costs/resources Project leader

5 Complete Confirm/Complete/Settle Project planner

6 Evaluate Execute reports Project leader

 SAP AG 1999
Maintenance History

Completed Completed
Notifications Orders

Damage Object
Description

Damage Work center


objects

Down Scheduling
Times of work

Activities Material
usage

Tasks Lists Costs by


class

 SAP AG 1999
Material Usage

Example: Use of material 100-100


from 01/01/01 to 01/01/02
Material Order Notification Functional Equipment Work ctr Reserved Unit Reservation Unit
location reference
100-200 901021 1000253 MECHMNT 2 PC 2 PC

901021 1000255 MECHMNT 1 PC 1 PC

901118 1000255 MECHMNT 2 PC 2 PC

901234 1000056 1000253 MECHMNT 1 PC 1 PC

901256 1000255 MECHMNT 2 PC 2 PC

100-200 904051 1000083 1000258 MECHMNT 18 PC 18 PC

18 PC 18 PC

 SAP AG 1999