Satyam SAP Level -1

Training for MPT

Plant Maintenance Module

Page 1
 Plant Maintenance Overview

Unit:1
Organization Levels

Unit:2 Unit:5
Technical Objects Refurbishment

Unit:3 Unit:6
Breakdown Maintenance Preventive Maintenance

Unit:4 Unit:7
Corrective Maintenance Reporting

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Page 3
 Location Based Organizational Structure

Maintenance Plant
At which operational system
of company are installed

Location e.g. site, building

It Subdivide a maintenance etc.
Plant according to Spatial criteria

Maintenance Work Centre e.g.technician

Its an organizational unit where machine
Work can be carried out

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 Planning based Organizational Structure

Maintenance Planning plant

Where maintenance requirements
are planned

Maintenance Planner groups

They defines planners within the
maintenance planning plant
e.g. mech. planner, electrical planner etc.

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 Types of Planning

Plant-Specific Planning
(Decentralized Planning)
In most organizational structures, the maintenance requirement
is planned in the same plant where it occurs ,the maintenance orders
are executed by workshops from the same plant and inventory is
maintained at same plant

Cross-Plant Planning
(Centralized Planning)
Multiple planning plants are assigned to a planning plant. In one
plant there is a need for maintenance, as a technical system there
requires maintenance.(= maintenance plant). All further functions
maintenance ,order execution, inventory management) are however,
the responsibility of another plant maintenance plant)

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 Planning Types
De-centralized Planning
Plant 1100
Maintenance Planning of
requirement Maintenance
requirements

Workshops

Plant 1000 Warehouse

Planning of
Maintenance
Inventory
Maintenance
requirements
requirement

Workshops

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 Planning Types
Centralized Planning
Plant 1200 Plant 1100
Maintenance
requirement

De-centralized
Maintenance Planning
requirement

Workshops

Plant 1000 Warehouse

Planning of
Maintenance
Inventory
Maintenance
requirements
requirement

Workshops

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 Work Center
A work center is an organizational unit within an operational system.

A work center can be one of the following:

Machine
Group of machines
Person
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 item
- Main work center in the task list header
- Performing work center in the operations for a task list
- Main work center in the order header
- Performing work center in the operations for an order

Work centers belong to the master data in PM and provide the capacity
required to perform a task.

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 Work center data

Work center data is used for the following business functions:

Basic Data - contains the description, work center category (for example,
Plant Maintenance) and planned usage, person responsible.

Capacities - The available capacity is usually the standard available capacity

with the specifications - factory calendar, work start and end, number of
individual capacities (= number of people) and shift time per capita. The
available capacity can be restricted according to time, or organized in shifts
different from the standard available capacity.

Scheduling - the operation dates are calculated based on the lead times
(duration of operation), starting from the basic start and end dates.

Personnel Data - in addition to defining available capacity, people (=

personnel numbers from Human Resources) or positions can be assigned in
the work center.

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 Available capacity in work center

Available capacity is the work that can be provided by a unit of

capacity at a work center for each working day.

The available capacity refers to the capacity available within a certain period. The
available capacity is determined by:

1. Work start and finish times.

2. Break lengths.
3. Capacity utilization level of the capacity units.
4. Number of individual capacity units that constitute the capacity.

The system stores the working time and the daily available capacity for each
work center.

The available capacity can be defined for one work center or for all work centers.

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Page 12
Technical Objects

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 Function Location
Function Locations are hierarchically ordered
structures that represent a technical system,
building, or part thereof
They are structured according to :
Spatial : E.g. Building 1, building 2

Technical : E.g. Press, Press frame, press

hydraulics

Functional : E.g. Polymerization, condensation

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Criteria for Functional Location

To represent the structure of technical systems

according to functional criteria

Recording of Maintenance tasks

Storage and Evaluation of Technical data

Cost monitoring by area

Effects of usage condition on the installed

equipment

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 Function Location (Master Record)

Equipments
General
Classification

Documents/Technical Drawings
Location
Multilingual text

Organization Address/Partner

Measuring Points/Counters

Structure
Permits

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 Function Location Features

To define the Functional Locations a template has to be used which is

called Structure Indicator.
The Structure Indicator helps in maintaining the hierarchies & control
usage of alphabets & numericals.
The newly created Functional Locations are automatically assigned to
its Superior Functional Location based on the Structure Indicator
Hierarchy.
The Functional Locations though assigned automatically, it can be
changed from the Structure tab in the Functional Location, by changing
the Superior FL.

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 Function Location Structure - Example

MPT

MPT-MOHP MPT-NMOHP

MPT- MPT- MPT- MPT- MPT-

MOHP- MOHP- MOHP- NMOHP- NMOHP-
UNLOAD CONV RECLAIM SCHOOL QUARTER

Page 18
 Equipment

Equipment is an individual physical object that is to be maintained

as an autonomous unit and for which maintenance
history should be constructed.

E.g. pumps, motors, vehicles etc.

Purpose of equipment :
To manage individual data for the object

Recording of maintenance tasks

Monitoring of maintenance tasks costs

Usage time of the object

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 Equipment Categories
Equipment categorisation is carried out using Equipment Category like

Machines

Fleet Objects

PRTs

Customer Equipment

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 Equipment (Master Record)

Equipment Usage
General
Documents/Classification
Technical Drawings

Location Multilingual text

Address/Partner

Organization Measuring Points/Counters

Permits
Structure
Internal Note

Page 21
 Fleet Objects - Features

Fleet Objects have specific data like

Identification Data
Number Plate, Chassis Number

Dimension Data Height, Width, Length

Transport Relevant
data Weight, Max Load, Loading Volume

Planning Data Counter Reading data

Other Features Fuel card Number, key Number

Engine Data Engine Type, Engine perf, RPM, CC

Fuel & Lub Data Fuel Type, Oil Type

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Using FLs & Equipment

A Functional Location having some

equipment installed.

One such equipment is a DG Set

Level-1 Sub equipment

Engine

Level -2 Sub Equipment

Engine Head

Level-3 Sub Equipment

Injectors

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Sub-Equipment

Page 24
 Classification of Equipment

Classification is a cross-application function in the R/3 System that

is used by other application as well as Plant Maintenance.

One aim of classification is to assign features in detail to a technical

object that the master record cannot handle in this quantity.

A classification
system describes
objects using
characteristics, and
grouping similar
objects into classes, to
classify them and
make them easier to
find.

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Characteristics

Page 26
 Class Hierarchy
Classes can be used in hierarchy for better classification of the equipment.
Multiple levels of Class Hierarchy is possible.

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 Object Networks
In a Industry different Networks could be there like, Eg: Water, Electricity,
Computer LAN, etc . These are to be defined in the system.

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 Object Links

By using the Object Links, the material flow can be easily known.
By taking a equipment for Maintenance, what other equipment are to be
stopped is also easily identifiable.
The Object links in reality can be Wires, Pipelines, etc.

Reclaimer

Conveyor - 1

Conveyor - 2 Ship

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 Bill of Material (BOM)

Bill of Material is a list of Materials for different uses in

different Modules

BOM Usage

Maintenance

Production

Engineering

Costing

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 BOM Usages

BOM is a list of materials which are relevant for a usage.

The Engineering /Design usage BOM records all components of a

product according to engineering/design criteria and contains their
technical data.
The Production usage BOM records the items according to
production criteria and assembly status.
The costing usage BOM maps the product structure and provides
the basis for automatic determination of the direct material costs for
a product.
The Plant Maintenance usage BOM contains items only relevant to
maintenance only.
And like wise other usages of the BOM.

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 BOM Use in Plant Maintenance

Structuring the Object

An Object should be structured as clearly as possible from a Maintenance

view point.

Spare Parts Planning

If a bill of Material is available for a maintenance object, this cab be easily

used to plan spares when planning a Maintenance Order.

Types of BOM in Plant Maintenance

BOMs for technical Objects ( FLs & Equipment).
BOMs for Materials.

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 BOM Records
The BOM is stored in the Master Record of the respective Object.
For a Equipment BOM, it is stored in the Master Record of the Equipment.
For a Functional Location BOM, it is stored in the Master Record of the
Functional Location.
For a Material BOM, it is stored in the Master Record of the Material.

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Page 34
 Breakdown Maintenance
Business Scenario

For breakdown maintenance, the data required for the other business
processes needs to entered quickly and easily so that the
subsequent steps can be executed.

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 Breakdown Maintenance order
Starting point is the creation of maintenance
order (possibly using data from the
Malfunction/ maintenance notification) for damage or a
Maintenance order malfunction. This is not a planned maintenance
order, but it is immediately released for
processing.

Execution It comprises the removal of spare parts from

stock and the actual execution of the order.

The actual time required is confirmed.

Technical confirmation are also entered to
Completion
record the repair and condition of the
technical system.

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 Breakdown Maintenance Order

Production Maintenance Planner

Breakdown
Report/call/ Order
message Create
and
Release

Technician
Maintenance Supervisor

Order
Malfunction
Complete
Correct/
Confirm

Page 37
 Order with or without Notification

Breakdown order can be created

directly without any previous
Order without requisition. It usually refers to a
Notification technical object (Function Location or
Equipment) and is configured at Work
Center.

Breakdown Order can also be

created in combination with a
maintenance notification, The order
Order with thereby contains the same data as
Notification in above case and the notification
contains all the data relevant for
the documentation or history e.g.
malfunction start or damage

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Page 39
 Corrective Maintenance

Notification Malfunctions and other requirements are recorded

E.g. Technical Object, Description, date,
Malfunction.

Orders are created and planned on the basis of notification

Planning E.g. Work to be performed, Material, Tools,
Internal/external resources

Order puts into process

Scheduling E.g. Order Release, Printout, Capacity Leveling
Availability Check

Order Executed
Execution E.g. Planned/Unplanned Material Withdrawn

Settlement of order done before or after this process

Completion E.g.Time Confirmation, Order Settlement, Technical
Completion, Technical Confirmation

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 Notification Category & Notification Type

The List of Standard Notification Categories & Types is shown below.

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 Maintenance Notification
It refers to a technical object and contains a description of the
malfunction or requirement like modification work it can also contain
data for constructing a history e.g. damage, causes and so on.

Date time reported by

Description
Notification Maintenance Object
Location data

Damage Location
Damage
Notification items
Cause of Damage

Activity
Activities Execution factors

Dates
Tasks
Task description

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 Priority
A priority can be assigned to each maintenance notification and order. This
priority defines the required start and end dates for the notification or order,
relative to the creation date.

Start Relevant start

maintenance Priority Type Priorities and unit
notification
PM 1
. 2 Relevant end
. . and unit
Notification
. .
sequence

During maintenance processing, you can work with internal priority types for
notifications and orders. Since you can define an unlimited number of priorities
for each priority type, it is easier for the user to utilize the same priority types
for notifications and orders; the same priority keys have the same meaning.

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 Catalog
For the coded entry of results and activities while
maintaining notifications which is useful for analysis

Catalog Damage

Code Mech-
Group anical

Page 44
 Catalogs
A cross-application catalog system is used for reporting maintenance
notifications. This catalog system has a hierarchical structure.

1. The first level of the catalog system is the catalog type. Each PM catalog
type represents a certain directory.
2. Each catalog type can be further subdivided using code groups.
3. You can define individual codes within each group.

Catalog Type Code groups Catalog Type

Damage Vehicles Torn drive belt

Cause of damage Buildings Broken axle
Activities Machines Ripped oil pan
Object parts . .
Tasks . .

Page 45
 Order Creating & Planning

Elements of Maintenance Order

Order Type, Dates, Plant, Reference Object,
Order Header Priority, Description, etc.

Equipment (assembly), function location,

Object list maintenance notification, etc.

Work Center, control key, description, standard

Operation time, activity type, salary details etc.

Material list Material, Quantity, Storage Location

Production
resources/tools

Settlement Rule

Costs

Page 46
 Scheduling

Scheduling in Preventive Maintenance orders

Scheduling is carried out for the operations based on different relationships

like FS,SS,FF,SF and also the logic backward or forward scheduling.

This will change the order basic start and end dates accordingly.

Scheduling in Corrective and Breakdown orders.

For breakdown orders there is no scheduling and only immediate execution

of the operations.

For corrective maintenance order there is no scheduling but earliest

execution of the operations in order.

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 Scheduling Parameters
During Scheduling, the lead times for the operations are totaled and either added to
Basic Start Data (Forward Scheduling) or subtracted from the Basic Finish date
(Backward Scheduling). These dates may differ from basic dates

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 Scheduling
In this order is subjected to various checks like material
availability and capacity requirements and required shop
papers are printed.
System can check in a single step whether all the
materials in the order are available, we use
availability check function for this.
System informs the result in an online message

If theres a lack of availability an error log can be

displayed that contains detail data about the
result of the check.

Material availability list can be displayed.

Depends upon availability check if planned

materials are not available in sufficient quantity,
system may or may not be able to release the
order depending upon customizing settings.

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 Permits

Permits are used to adhere to health and safety regulations, and

control order processing.
Permits can be used in two different ways.
As Technical permits assigned directly to the Technical Objects.
As process oriented permits with automatic assignment to the
order.

Technical Permits are assigned manually to the technical Object and

not classified (Eg: welding permit). If an order is created for the
technical object. The permits are copied to the order and can influence
the order release with a corresponding setting.

Process Oriented permits are determined automatically based on a

field in the order header (for Eg: Planned costs) and can likewise
influence the order release. Automatic determination is based on the
classified of the permit.

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 Order Release

Reservation Effective

Papers can be printed

Confirmation Possible

Material can be withdrawn

Book good receipts

Complete Task

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 Maintenenance Order - Printing Papers

Job Ticket Time Ticket

It gives the person Time required to
executing the mainten- execute the operation
ance work a complete
overview of the order.

Control Ticket Confirmation slip

Shows to maintenance Used by workers as an
engg. a complete entry sheet for their
overview of the order. work times

Material Pick List Material withdrawl

Shows which material slip
has been planned for Authorizes the person
Object List
the order. to take material from
Shows overview of the
warehouse for
Object (Technical
order
object, notifications)
in the order

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 Execution

It Involves the withdrawl of spare parts from the

warehouse and actual execution of the order.

Pick List

Planned/unplanned
material withdrawl

Order
Execution as
per
operations

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 Completion

After the work has been completed, the actual time required is
confirmed in the fifth and final step in Time Confirmation.

The Technical findings (damage, repairs performed, and so on..) and

the effects on the assets condition are recorded in the Technical
Confirmation (TECO).

Technical confirmation indicates that the order is finished for Plant

Maintenance.

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Time Confirmation

Individual Entry

Collective entry

Collective Entry
using
operation list

Overall
completion
confirmation

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 Results of TECO

Limited ability to change

order

Status Technically completed

Create Settlement rule

Deletion flag for purchase

requisition

Close open reservation

Close open capacities

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Page 57
 Refurbishment

Production

Intact Defect

New Stores To Scrap

Refurbished To be Refurbished

Workshop / External Place

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 Valuation Category & Types

Valuation
Reference Condition Origin
categories

C1
I New Part D
Internal Domestic
C2
E
Valuation External
Refurbished A
Abroad
Types C3
Defective

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Price of Split Valuated Material

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 Refurbishment - Cycle

Equipment Removal Warehouse Issue +

+ Goods Receipt Refurbishment

1 2
(Serialized Equipment)
Functional Location

Work Centre
4 3

Goods Issue + Return to Warehouse

Equipment Installation
Warehouse

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 Refurbishment

Process in SAP

A refurbishment Order is created in Order type PM 04

The Order is to be created on the material with respective plant &

storage Location.

The Order should contain the number of pieces to be refurbished.

Plan the material & Manpower required for the refurbishment.

Withdraw the material from the stores.

Carryout the refurbishment of spares.

Carryout the Complete confirmation.

Post the Refurbished goods posting back to Stores.

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Page 63
 Preventive Maintenance
To keep downtime and maintenance costs to a minimum, the technical
system in a company are inspected and maintained regularly.

Preventive maintenance is performed based on time, the condition or

the performance of the technical object.
Preventive
Maintenance

Time -based Performance

based

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Preventive Maintenance

Page 65
 Process for Preventive Maintenance
It defines the steps to be carried
Task List out on an object-dependent or
object independent basis
It is created for the object and is
Maintenance used to automatically generate
Plan orders, notification or service entry
sheet with certain specification
It is used to regularly call orders,
Schedule notification or service entry sheet
and to recalculate planned dates
Order is automatically generated
Maintenance from the maintenance plan and
included in the order list, where it
Order
is processed like other orders
It flags the order and planned date
Technical in the maintenance plan as complete,
date of technical completion is
Completion used to calculate next planned date

MFG. COMPETENCY Page

PM-03
66
(PP,PM&QM) Page 66
 Task List

Maintenance task lists describe a series of individual maintenance

activities.

Task lists also specify which spare parts and tools are required for
operations and the time needed to perform the work.

If maintenance task lists is created, Maintenance orders can be created

and maintenance plans very easily, as operations and processes are
already entered in the maintenance task list.

If the same task is required again shortly afterwards, maintenance order

can be created with reference to the maintenance task list.

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 Single Cycle maintenance Planning
A maintenance plan is used to generate a call object
automatically for a particular date.

A call object can be a maintenance order, notification or

service entry sheet. Order and notification can also be
generated at the same time.

Structure of Maintenance Plan

Scheduling data It contains the scheduling parameters for

the plan
It contains following data entries :
> Planning data
Maintenance item
> Reference object
> Task list

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 Single Cycle Plan Scheduling Parameters

While creating single cycle plan, the cycle is assigned, that is, the
period until each planned date (which is the due date of the measure.
Orders are generated based on planned date.

Cycle
3 months

However , the call date (which is the order creation date) falls before
the planned date, to allow a certain lead time (for material
procurement).

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 Single Cycle Plan Scheduling Parameters

Cycle start defines the date from which the calculation of the planned
dates should begin.
Planned
date

Scheduling Period
(1 Year)

Scheduling period specifies the period for which planned dates should be
calculated in advance. It can be used for time-based and performance
based preventive maintenance.

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 Strategy Plan

Business Scenario

Maintenance work and inspections are performed in different cycles.

Example: Service record for a fleet object (excerpt)

o Check fan belt: every 12 months

o Change fan belt: every 24 months
o Change oil: every 6 months
o Change oil filter: every 12 months
o Check air filter: every 12 months
o Change air filter: every 24 months

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 Single Cycle Plan Scheduling Parameters

Cycle start & Offset defines the date from which the calculation of the
planned dates should begin & which package should be in sequence.
Planned
date

H Q Y Q

Scheduling Period
(1 Year)

Scheduling period specifies the period for which planned dates should be
calculated in advance. It can be used for time-based and performance
based preventive maintenance.

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 Performance based strategy planning

Preventive maintenance can be planned and performed using a

performance-based strategy and regularly entered counter
readings. The maintenance dates calculated are adjusted
automatically based on the counter readings entered.

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 Basic Scheduling Functions
The scheduling of performance-based maintenance plans is based on the estimated
annual performance, which has been entered in the counter for the reference
object.
The daily performance is then calculated from the estimated annual performance.

A time period is then calculated from the daily Calculated performance and
maintenance cycle. Planned
By adding this time period to the start date of date the maintenance plan,
a new planned date is reached.

Cycle :
20,000 liters.
Example:

Estimated annual performance: 36,500 liters

Internal calculation of daily performance: 36.500 : 365 days = 100 liters per day
Planned date for a cycle of 20,000 liters: 20.000 : 100 = 200 days,
This means that, beginning from the cycle start, the first planned date is set after 200
days.

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 Multiple counter Plan
A multiple counter plan is a maintenance plan that can have cycles of different
dimensions. You can assign cycles freely to the multiple counter plan. A strategy cannot
be used here.
Based on the cycles entered, the counters from the reference object are proposed by
comparing the units.

Business
Scenario

For an airline company, changing the engine is dependent on two criteria:

Number of flying hours
Number of take-offs/landings
The engine should be replaced either after 18,000 flying hours or after
12,000 take-offs/landings.
A multiple counter plan, in which the two characteristics "Flying hours" and "Take-
offs/landings" are linked, can be used here for planning and executing this task.

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Page 76
 Usage List History

It displays phases, during which the equipment was installed at a functional

location, assigned directly to a usage site (for example, a cost center), or stored in
a warehouse.
The usage list displays all the pieces of equipment that have been installed in
chronological order.

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 Maintenance history

Analyses in maintenance processing are based on completed notifications or orders and historical orders.
Completed notifications and orders
A notification is transferred to the notification history when completed, whereas an order is
transferred to the section for completed orders.
Evaluations can be performed in the corresponding list editing function, where the status "Completed"
must be set each time.
Historical orders
Historical orders are generated when completed orders are archived and they form the basis for long-term
analyses. They are transferred to the order history. Evaluations can be performed in the list editing
function for the orders, where the status "Historical" must be set.

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 Maintenance Cost Analysis

Standard Maintenance Cost Analysis are present in SAP.

Analysis based on

Functional Locations
Equipment
Work Center
Object Type
Order Types
Maintenance Activity Types
Plant Sections
ABC Analysis
MTBF, MTTR etc.

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