SAP Plant Maintenance Training SAP Overview Agenda PM Organization Structure 1.1 Maintenance Plant & Maintenance Planning Plant 1.2 Maintenance Planner Group & Maintenance Work Center Technical Objects 2.1 2.2 2.3 2.4 Functional Location Equipment Bill of Material Measuring Point Maintenance Processing 3.1 Breakdown/Corrective Maintenance 3.2 Preventive Maintenance 3.2 Refurbishment Order PM Information System © 2009 Semen Gresik Group / Page PM Organization Structure Maintenance Plant : Is organizational unit where you can manage technical objects and work center Maintenance Plant Maintenance Planning Plant : Is organizational units where task list, material planning, maintenance plans are managed, maintenance notification are created and maintenance orders can be handled Maintenance Planning Plant Maintenance Work Center Is a group persons who responsible to task Planner Group Group of employees for the planning and processing of maintenance tasks in a particular plant Planner Group © 2009 Semen Gresik Group / Page Maintenance Work Center Maintenance Work Center Work Center can be one of the following : Machine Group of machines People Group of people In Plant Maintenance work centers are used as: Main work center in the master record for the equipment or functional location Main work center in a maintenance planning Main work center in the task list header Main work center in the order header © 2009 Semen Gresik Group / Page Functional Location Functional Location Functional location = multi-level, hierarchical structure, Functional Location represents the place at which a maintenance task is to organized according to be performed Spatial Technical Pieces of equipment can be installed & dismantled at functional locations Functional The costs of maintenance task have to be monitored for certain parts of your technical system SAP AG 1999 © 2009 Semen Gresik Group / Page Criteria Structure Indicator Functional location = multi-level, hierarchical structure, organized according to Spatial Technical Structure Indicator Functional Criteria Edit mask Hierarchy levels Location number © 2009 Semen Gresik Group / Page SAP AG 1999 AN-ANN-N-X-X 56 A1 A1-B A1-B02 A1-B02- A1-B02- 9-C A1-B02- 9-C- A = Alpha N = Numeric X = Alphanumeric System Area Sub-area Function Sub-function Item Automatic Assignment Upon Creation Automatic Assignment Upon Creation C1 Clarification plant Existing functional locations C1-M Mechanical cleaning C1-M01 Sand trap New functional locations SAP AG 1999 © 2009 Semen Gresik Group / Page C1-B Biological cleaning C1-M02 Oil/fat trap C1-M01-2 Ventilator Ventilator C1-B01 Pump plant C1-M02-2 Ventilator C1-B01-1 Pump C1-B02-2 Filter cell C1-B02 Filtering station Equipment A pieces of equipment is an individual physical object that is to be maintained as an autonomous unit Equipment can be installed at functional location You should always create an equipment master record for a technical object if: You need to manage individual data for the object Breakdown, prepared or preventive maintenance task are required for an object and must be recorded The costs of maintenance tasks for this object are to be monitored You need to record the usage time of this object at functional location Technical data for this object must be collected and evaluated over long periods of time © 2009 Semen Gresik Group / Page Autonomous Equipment Equipment Autonomous Equipment category: Machine Equipment category: Fleet object SAP AG 1999 © 2009 Semen Gresik Group / Page Equipment category: Production resources and tools Equipment category: Test equipment Autonomous Equipment Hierarchy Autonomous Equipment Hierarchy Level Superior Equipment: Fleet object Level Sub-equipment: Drive unit Level Sub-equipment: Gears Level Sub-equipment: Shaft SAP AG 1999 © 2009 Semen Gresik Group / Page 10 Management of Task Lists: Business Scenario Management of Task List 10 Switch off 20 Dismantle 30 Clean 40 Reassemble 50 60 Which operations have to be performed? SAP AG 2001 © 2009 Semen Gresik Group / Page 38 Material PRT Target time Inspection characteristic Preventive Maintenance © 2009 Semen Gresik Group / Page 39 Single Cycle Plan Single Cycle Plan: Business Process 1999 94 96 98 1997 2000 I must perform the same inspections at regular intervals SAP AG 1999 © 2009 Semen Gresik Group / Page 40 Inspection of "Portable fire extinguishers" Structure of Maintenance Plan Structure of Maintenance Plan Interval (cycle) Maintenance plan months Scheduling data Maintenance item Maintenance item Reference object Task list Responsibilities / Planning data SAP AG 2001 © 2009 Semen Gresik Group / Page 41 Strategy Plan: Business Process Strategy Plan External visual inspection Internal visual inspection Check gear teeth for wear Which parts must be maintained at which intervals? SAP AG 1999 © 2009 Semen Gresik Group / Page 42 Maintenance MaintenanceStrategy Strategy 1997 Scheduling indicator Package definition Time - factory calendar months Strategy SAP AG 1999 © 2009 Semen Gresik Group / Page 43 months months Tasklist List Maintenance Strategy Task & and Maintenance Strategy Task list 0010 Switch off 0020 Safety check 0030 External visual check 0040 Change seal 0050 Exchange H9 casing 0060 Check Z7 wire SAP AG 1999 © 2009 Semen Gresik Group / Page 44 Strategy Multiple Counter Plan © 2009 Semen Gresik Group / Page 45 Cycle Start Planned Date Cycle Start&and Planned Date Order 901760 Maintenance plan Order exactly on planned date? Scheduling data Planned date Maintenance item Cycle start SAP AG 2001 © 2009 Semen Gresik Group / Page 46 Cycle months Maintenance Scheduling Overview Maintenance Scheduling Overview Maintenance item report, sorted by equipment (no.) 1998 or as a list With display variants With general list viewer SAP AG 1999 © 2009 Semen Gresik Group / Page 47 as a graphic With maintenance plan simulation With/without details 1999 Refurbishment Order The PM application component supports the refurbishment of defective repairable spares, which is critical for system availability in many companies You can represent this core maintenance process by integrating Plant Maintenance with the Materials Management (MM) component © 2009 Semen Gresik Group / Page 48 Valuation Category & Valuation Type Valuation categories Valuation types R=Reference C=Condition I Internal C1 New part E External O=Origin D Domestic C2 Refurbished C3 Defective SAP AG 1999 © 2009 Semen Gresik Group / Page 49 A Abroad Settlement of Refurbishment Order Settlement Of Refurbishment Order Warehouse Material P-2001 as new C3 Order Work ctr C2 C1 902059 PM 04 Refurbishment refurbished Pump P-2001 C2 Settlement faulty C3 SAP AG 2001 © 2009 Semen Gresik Group / Page 50 PM Information System MAINTENANCE OBJECTS MAINTENANCE PLANNING MAINTENANCE PROCESSING UPDATING DATA -ABC analysis STANDARD ANALYSIS FLEXIBLE ANALYSIS -Classification -Planned/actua l comparison -Cumulative LOCATION-BASED MANUFACTURED-BASED - NOTIFICATION AND BREAKDOWN ANALYSIS - COST INFORMATION © 2009 Semen Gresik Group / Page 51 freq Curve -Correlation Thank you! © 2009 Semen Gresik Group / Page 52 © SAP 2008 / Page 52 ... © 2009 Semen Gresik Group / Page Autonomous Equipment Equipment Autonomous Equipment category: Machine Equipment category: Fleet object SAP AG 1999 © 2009 Semen Gresik Group / Page Equipment... tools Equipment category: Test equipment Autonomous Equipment Hierarchy Autonomous Equipment Hierarchy Level Superior Equipment: Fleet object Level Sub-equipment: Drive unit Level Sub-equipment:... installation times for a piece of equipment from SAP AG 1999 both the functional location view and the equipment view © 2009 Semen Gresik Group / Page 11 Equipment EquipmentUsage Usage List List S-15