Satyam SAP Level -1 Training for MPT

Plant Maintenance Module

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Plant Maintenance Overview

Unit:1 Organization Levels Unit:2 Technical Objects Unit:3 Breakdown Maintenance

Unit:5 Refurbishment
Unit:6 Preventive Maintenance Unit:7 Reporting

Unit:4 Corrective Maintenance

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Location Based Organizational Structure Maintenance Plant

At which operational system

of company are installed

It Subdivide a maintenance Plant according to Spatial criteria

Location

e.g. site, building etc.

Maintenance Work Centre

Its an organizational unit where Work can be carried out

e.g.technician machine

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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

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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Cross-Plant Planning (Centralized Planning)

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

Plant 1100

Workshops
Planning of Maintenance requirements

Plant 1000
Maintenance requirement

Warehouse Inventory

Workshops

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Planning Types
Centralized
Plant 1200
Maintenance requirement

Planning
Maintenance requirement

Plant 1100

De-centralized

Planning
Workshops

Planning of Maintenance requirements

Plant 1000
Maintenance requirement

Warehouse Inventory

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. 2. 3. 4. Work start and finish times. Break lengths. Capacity utilization level of the capacity units. 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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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 Multilingual text

Location

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

MPTMOHPUNLOAD

MPTMOHPCONV

MPTMOHPRECLAIM

MPTNMOHPSCHOOL

MPTNMOHPQUARTER

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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 Multilingual text Address/Partner

Location

Organization

Measuring Points/Counters Permits

Structure
Internal Note

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Fleet Objects - Features

Fleet Objects have specific data like
Identification Data Dimension Data

Number Plate, Chassis Number Height, Width, Length Weight, Max Load, Loading Volume Counter Reading data Fuel card Number, key Number

Transport Relevant data

Planning Data Other Features

Engine Data
Fuel & Lub Data

Engine Type, Engine perf, RPM, CC

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

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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

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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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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

Malfunction/ Maintenance order
Starting point is the creation of maintenance order (possibly using data from the maintenance notification) for damage or a 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.

Completion

The actual time required is confirmed. Technical confirmation are also entered to record the repair and condition of the technical system.

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Breakdown Maintenance Order

Production Maintenance Planner

Breakdown Report/call/ message

Order Create and Release

Technician Maintenance Supervisor Malfunction Correct/ Confirm Order Complete

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Order with or without Notification

Breakdown order can be created directly without any previous requisition. It usually refers to a 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 thereby contains the same data as in above case and the notification contains all the data relevant for the documentation or history e.g. malfunction start or damage

Order without Notification

Order with Notification

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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 E.g. Work to be performed, Material, Tools, Internal/external resources Order puts into process E.g. Order Release, Printout, Capacity Leveling Availability Check

Planning

Scheduling

Execution

Order Executed E.g. Planned/Unplanned Material Withdrawn

Completion

Settlement of order done before or after this process 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

Notification

Description Maintenance Object Location data

Damage Location

Notification items Activities Tasks

Damage Cause of Damage Activity Execution factors

Dates 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 maintenance notification

Priority Type PM . . .

Priorities 1 2 . .

Relevant start and unit

Notification sequence

Relevant end and unit

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 Group

Mechanical

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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 Damage Cause of damage Activities Object parts Tasks

Code groups
Vehicles Buildings Machines . .

Catalog Type Torn drive belt Broken axle Ripped oil pan . .

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Order Creating & Planning Elements of Maintenance Order

Order Header Object list Operation
Order Type, Dates, Plant, Reference Object, Priority, Description, etc. Equipment (assembly), function location, maintenance notification, etc. Work Center, control key, description, standard time, activity type, salary details etc. Material, Quantity, Storage Location

Material list Production resources/tools Settlement Rule Costs

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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 executing the maintenance work a complete overview of the order.

Time required to execute the operation

Control Ticket

Confirmation slip
Used by workers as an entry sheet for their work times

Shows to maintenance engg. a complete overview of the order.

Material Pick List

Shows which material has been planned for the order.

Material withdrawl slip

Object List
Shows overview of the Object (Technical object, notifications) in the order Authorizes the person to take material from warehouse for 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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Refurbishment
Production

Intact

Defect

New

Stores

To Scrap

Refurbished

To be Refurbished

Workshop / External Place

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Valuation Category & Types

Valuation categories Reference Condition Origin

I Internal

C1 New Part C2 Refurbished C3 Defective

D Domestic

Valuation Types

E External

A Abroad

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Price of Split Valuated Material

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Refurbishment - Cycle

Equipment Removal + Goods Receipt

Warehouse

Issue + Refurbishment

1
(Serialized Equipment) Functional Location

2
Work Centre

4
Goods Issue + Equipment Installation

3
Return to Warehouse

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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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

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Process for Preventive Maintenance

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

Schedule

Maintenance Order Technical Completion

MFG. COMPETENCY (PP,PM&QM)

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 > Reference object > Task list

Maintenance item

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

Y
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 maintenance cycle. Planned By adding this time period to the start date of date a new planned date is reached.

performance and
the maintenance plan,

Example:

Cycle : 20,000 liters.

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 "Takeoffs/landings" are linked, can be used here for planning and executing this task.
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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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