LO100 - Plant Maintenance-4.6C

LO100 Instandhaltung LO100

Release 46C 26.03.2002

LO100 Instandhaltung.............................................................................................................................................0-1 Copyright.............................................................................................................................................................0-2 Plant Maintenance (PM)..................................................................................................................................0-3 Course Prerequisites........................................................................................................................................0-4 Target Group....................................................................................................................................................0-5 Course Overview.................................................................................................................................................1-1 Course Goal.....................................................................................................................................................1-2 Course Content................................................................................................................................................1-3 Course Overview Diagram..............................................................................................................................1-4 Main Business Scenario...................................................................................................................................1-5 Navigation............................................................................................................................................................2-1 Navigation: Unit Objectives............................................................................................................................2-2 Navigation: Business Scenario........................................................................................................................2-3 Logging On to the System...............................................................................................................................2-4 SAP Easy Access - Standard............................................................................................................................2-5 Role-Based User Menu....................................................................................................................................2-6 Screen Elements...............................................................................................................................................2-7 Selecting Functions..........................................................................................................................................2-8 Field Help: F1 and F4......................................................................................................................................2-9 Menus: System and Help...............................................................................................................................2-10 SAP Library...................................................................................................................................................2-11 User-Specific Personalization........................................................................................................................2-12 Personalizing the Frontend with GuiXT........................................................................................................2-13 Elements of the Workplace............................................................................................................................2-14 Active Applications (In Use).........................................................................................................................2-15 Workplace Favorites......................................................................................................................................2-16 Personalizing MiniApps................................................................................................................................2-17 Workplace: Advantages.................................................................................................................................2-18 Navigation: Unit Summary............................................................................................................................2-19 Navigation - Exercises...................................................................................................................................2-20 Navigation - Solutions...................................................................................................................................2-25 Organization of Plant Maintenance.....................................................................................................................3-1 Organization of Plant Maintenance: Unit Objectives......................................................................................3-2 Course Overview Diagram..............................................................................................................................3-3 Organization of Plant Maintenance: Business Scenario..................................................................................3-4 Organization of Plant Maintenance: General Considerations..........................................................................3-5 Types of Maintenance......................................................................................................................................3-6 Product Lifecycle Management (PLM)...........................................................................................................3-7 Asset Life-Cycle Management (ALM)............................................................................................................3-8 Plant Maintenance Integration.........................................................................................................................3-9 Organization of Plant Maintenance: Plant Maintenance Organizational Structures.....................................3-10 Organizational Structures in Plant Maintenance............................................................................................3-11 Cross-Plant Maintenance...............................................................................................................................3-12 Roles in Plant Maintenance...........................................................................................................................3-13 Role Functions...............................................................................................................................................3-14 Single Roles...................................................................................................................................................3-15 Maintenance Work Centers............................................................................................................................3-16 Work Center: Contents...................................................................................................................................3-17 Work Center: Main Functions........................................................................................................................3-18 Organization of Plant Maintenance: Summary..............................................................................................3-19

Exercises........................................................................................................................................................3-20 Solutions........................................................................................................................................................3-26 Technical Objects.................................................................................................................................................4-1 Technical Objects: Unit Objectives.................................................................................................................4-2 Course Overview Diagram..............................................................................................................................4-3 Technical Objects: Business Scenario.............................................................................................................4-4 Technical Objects: Phases and Roles...............................................................................................................4-5 Technical Objects: Functional Locations.........................................................................................................4-6 Functional Location.........................................................................................................................................4-7 Criteria for Functional Locations.....................................................................................................................4-8 Structure Indicator...........................................................................................................................................4-9 Master Record for Functional Location.........................................................................................................4-10 Automatic Assignment Upon Creation..........................................................................................................4-11 Example of Functional Location Structure....................................................................................................4-12 Technical Objects: Equipment.......................................................................................................................4-13 Equipment......................................................................................................................................................4-14 Criteria for Equipment Master Record..........................................................................................................4-15 Equipment Master Record.............................................................................................................................4-16 Installation/Dismantling of Equipment..........................................................................................................4-17 Prerequisites for Equipment Installation........................................................................................................4-18 Equipment Usage List....................................................................................................................................4-19 Technical Objects: Bills of Material..............................................................................................................4-20 Bills of Material in a Company......................................................................................................................4-21 Bills of Material in Plant Maintenance..........................................................................................................4-22 Bills of Material: Example of Material BOM................................................................................................4-23 Technical Objects: Unit Summary.................................................................................................................4-24 Exercises........................................................................................................................................................4-25 Technical Objects: Solutions.........................................................................................................................4-30 Breakdown Maintenance.....................................................................................................................................5-1 Breakdown Maintenance: Unit Objectives......................................................................................................5-2 Course Overview Diagram..............................................................................................................................5-3 Breakdown Maintenance: Business Scenario..................................................................................................5-4 Breakdown Maintenance: Entering an Order..................................................................................................5-5 Cycle of Maintenance Processing....................................................................................................................5-6 Cycle of Breakdown Maintenance...................................................................................................................5-7 Business Process for Breakdown Maintenance...............................................................................................5-8 Order: With or Without Notification................................................................................................................5-9 Maintenance Processing Instruments.............................................................................................................5-10 Maintenance Order: Putting in Process..........................................................................................................5-11 Breakdown Maintenance: Task Completion..................................................................................................5-12 Time Confirmations.......................................................................................................................................5-13 Maintenance Order: Technical Completion...................................................................................................5-14 Breakdown Maintenance: Unit Summary......................................................................................................5-15 Processing Malfunction-based Plant Maintenance: Exercises.......................................................................5-16 Solutions........................................................................................................................................................5-25 Corrective Maintenance.......................................................................................................................................6-1 Corrective Maintenance: Unit Objectives........................................................................................................6-2 Course Overview Diagram..............................................................................................................................6-3 Corrective Maintenance: Business Scenario....................................................................................................6-4 Corrective Maintenance: Notification of Maintenance Requirements............................................................6-5 Cycle for Corrective Maintenance...............................................................................................................6-6

Maintenance Notification: Structure............................................................................................................6-7 Objects in Maintenance Notification...........................................................................................................6-8 Maintenance Notification: Object Information............................................................................................6-9 Catalogs.....................................................................................................................................................6-10 Catalogs and Catalog Profiles....................................................................................................................6-11 Selecting Maintenance Notifications.........................................................................................................6-12 Selection Hit List: ABAP List Viewer.......................................................................................................6-13 Notification of Maintenance Requirements: Exercises.............................................................................6-14 Notification of Maintenance Requirements: Solutions..............................................................................6-17 Corrective Maintenance: Planning of Orders................................................................................................6-19 Cycle for Corrective Maintenance.............................................................................................................6-20 Planning Alternatives: Internal or External Processing?...........................................................................6-21 Creation of Maintenance Orders................................................................................................................6-22 Elements of Maintenance Order................................................................................................................6-23 Operations..................................................................................................................................................6-24 Maintenance Order: Object list..................................................................................................................6-25 Stock Material - Process Flow...................................................................................................................6-26 Non-Stock Material - Process Flow...........................................................................................................6-27 Central Address Management....................................................................................................................6-28 Cost Analysis in Maintenance Order.........................................................................................................6-29 Planning of Orders: Exercises....................................................................................................................6-30 Planning of Orders: Solutions....................................................................................................................6-36 Corrective Maintenance: Scheduling of Maintenance Tasks.........................................................................6-41 Cycle for Corrective Maintenance.............................................................................................................6-42 Selecting Maintenance Orders...................................................................................................................6-43 Selection Hit List: ABAP List Viewer.......................................................................................................6-44 Maintenance Order: Multi-Level Order Lists............................................................................................6-45 Resource Planning: Availability check......................................................................................................6-46 Material Availability List...........................................................................................................................6-47 Order Release.............................................................................................................................................6-48 Maintenance Order: Printing.....................................................................................................................6-49 Maintenance Order: Delta Printing............................................................................................................6-50 Exercises....................................................................................................................................................6-51 Solutions....................................................................................................................................................6-54 Corrective Maintenance: Execution of Maintenance Tasks...........................................................................6-58 Cycle for Corrective Maintenance.............................................................................................................6-59 Material Withdrawal..................................................................................................................................6-60 Exercises....................................................................................................................................................6-61 Solutions....................................................................................................................................................6-63 Corrective Maintenance: Completion of Notifications and Orders...............................................................6-65 Cycle for Corrective Maintenance.............................................................................................................6-66 Order Completion Confirmation: Times / Activities.................................................................................6-67 Technical Confirmation (1)........................................................................................................................6-68 Technical Confirmation (2)........................................................................................................................6-69 Overall Completion Confirmation.............................................................................................................6-70 Maintenance Order: Technical Completion (1).........................................................................................6-71 Maintenance Order: Technical Completion (2).........................................................................................6-72 Reverse Technical Completion..................................................................................................................6-73 Maintenance Notification: Complete.........................................................................................................6-74 Action Log.................................................................................................................................................6-75 Document Flow..........................................................................................................................................6-76

Corrective Maintenance: Summary...........................................................................................................6-77 Completion of Order and Notification: Exercises.....................................................................................6-78 Completion of Order and Notification: Solutions......................................................................................6-83 External Services.................................................................................................................................................7-1 External Services: Unit Objectives..................................................................................................................7-2 Course Overview Diagram..............................................................................................................................7-3 External Services: Business Scenario..............................................................................................................7-4 External Services: Basics of External Services...............................................................................................7-5 How is an External Service Triggered?...........................................................................................................7-6 Outsourcing......................................................................................................................................................7-7 External Services: External Services as Individual Purchase Order................................................................7-8 Individual Purchase Order: Phases and Roles.................................................................................................7-9 External Assignment Based on Hours or Fixed Price....................................................................................7-10 Creating an Individual Purchase Order..........................................................................................................7-11 Order Status for Goods Receipt.....................................................................................................................7-12 Invoice Verification........................................................................................................................................7-13 External Services: External Services with External Company Work Centers...............................................7-14 External Work Center: Phases and Roles.......................................................................................................7-15 Prerequisites...................................................................................................................................................7-16 Set Up Order..................................................................................................................................................7-17 Confirm Order................................................................................................................................................7-18 Settling a Maintenance Order........................................................................................................................7-19 Billing Document and Controlling................................................................................................................7-20 External Services: External Services as Service Items..................................................................................7-21 Service Procurement: Phases and Roles........................................................................................................7-22 Service Master Record...................................................................................................................................7-23 Model Service Specifications........................................................................................................................7-24 Maintenance Order with Service Items.........................................................................................................7-25 Maintenance Order and Purchase Requisition...............................................................................................7-26 Purchase Requisition and Purchase Order.....................................................................................................7-27 Entry Sheets for Services Provided...............................................................................................................7-28 Cost Update in Order.....................................................................................................................................7-29 External Services: Unit Summary..................................................................................................................7-30 External services as individual purchase order: Exercises............................................................................7-31 External services as individual purchase order: Solutions.............................................................................7-52 Work Clearance Management (WCM)................................................................................................................8-1 Work Clearance Management: Unit Objectives..............................................................................................8-2 Course Overview Diagram..............................................................................................................................8-3 Work Clearance Management: Business Scenario..........................................................................................8-4 Need for WCM................................................................................................................................................8-5 WCM and the Maintenance Process................................................................................................................8-6 Architecture.....................................................................................................................................................8-7 Work Clearance Document..............................................................................................................................8-8 Phases and Roles Standard Model (1).............................................................................................................8-9 Phases and Roles: Standard Model (2)..........................................................................................................8-10 Standard Model: Example..............................................................................................................................8-11 Work Clearance Management: Summary......................................................................................................8-12 Preventive Maintenance.......................................................................................................................................9-1 Preventive Maintenance: Unit Objectives.......................................................................................................9-2 Course Overview Diagram..............................................................................................................................9-3 Preventive Maintenance: Business Scenario...................................................................................................9-4

Preventive Maintenance: Basics......................................................................................................................9-5 Types of Preventive Maintenance....................................................................................................................9-6 Preventive Maintenance: Phases and Roles.....................................................................................................9-7 Preventive Maintenance: Task List..................................................................................................................9-8 Task List...........................................................................................................................................................9-9 Maintenance Task Lists: Structure.................................................................................................................9-10 Preventive Maintenance: Single Cycle Plan..................................................................................................9-11 Single Cycle Plan: Business Process.............................................................................................................9-12 Scheduling Data and Maintenance Item........................................................................................................9-13 Using a Task List to Include an Operation List.............................................................................................9-14 Preventive Maintenance: Strategy Plan.........................................................................................................9-15 Strategy Plan: Business Process....................................................................................................................9-16 Maintenance Strategy....................................................................................................................................9-17 Maintenance Package....................................................................................................................................9-18 Task List and Maintenance Strategy..............................................................................................................9-19 Creating a Time-Based Strategy Plan............................................................................................................9-20 Preventive Maintenance: Maintenance Plan Scheduling...............................................................................9-21 Schedule Maintenance Plans.........................................................................................................................9-22 Cycle Start and Planned Date........................................................................................................................9-23 Maintenance Scheduling Overview...............................................................................................................9-24 Preventive Maintenance: Summary...............................................................................................................9-25 Task list: Exercises.........................................................................................................................................9-26 Task list: Solutions.........................................................................................................................................9-35 Refurbishment....................................................................................................................................................10-1 Refurbishment: Material Master....................................................................................................................10-2 Refurbishment: Unit Objectives....................................................................................................................10-3 Course Overview Diagram............................................................................................................................10-4 Refurbishment: Business Scenario................................................................................................................10-5 Refurbishment Phases and Roles...................................................................................................................10-6 Valuation Category and Valuation Type........................................................................................................10-7 Valuation Category and Type in Material Master..........................................................................................10-8 Condition-Based Material Valuation.............................................................................................................10-9 Moving Average Price.................................................................................................................................10-10 Refurbishment: Refurbishment Order..........................................................................................................10-11 Refurbishment Order...................................................................................................................................10-12 Refurbishment Order: Stock Withdrawal....................................................................................................10-13 Refurbishment Order: Inward Stock Movement.........................................................................................10-14 Effect of Refurbishment on Stock Value of Material...................................................................................10-15 Refurbishment: Unit Summary....................................................................................................................10-16 The Material Master: Exercises...................................................................................................................10-17 The Material Master: Solutions...................................................................................................................10-24 Reporting and Analyses.....................................................................................................................................11-1 Reporting and Analyses: Unit Objectives......................................................................................................11-2 Course Overview Diagram............................................................................................................................11-3 Reporting and Analyses: Business Scenario..................................................................................................11-4 Reporting and Analyses: Maintenance History..............................................................................................11-5 Evaluations: Phases and Roles.......................................................................................................................11-6 Usage List......................................................................................................................................................11-7 Maintenance History......................................................................................................................................11-8 Material Usage...............................................................................................................................................11-9 Reporting and Analyses: Evaluations and Analyses....................................................................................11-10

Data Flow in LIS..........................................................................................................................................11-11 Organization of Information Structures.......................................................................................................11-12 Information Structures in Plant Maintenance..............................................................................................11-13 Standard Analysis Options...........................................................................................................................11-14 Standard Report in CO.................................................................................................................................11-15 Reporting and Analyses: Unit Summary......................................................................................................11-16 Evaluations and analyses: Exercises............................................................................................................11-17 Evaluations and analyses: Solutions............................................................................................................11-19 Summary and Outlook.......................................................................................................................................12-1 Summary and Outlook: Business Processes..................................................................................................12-2 Summary and Outlook: Unit Objectives........................................................................................................12-3 Course Overview Diagram............................................................................................................................12-4 Business Process: Breakdown Maintenance..................................................................................................12-5 Business Process: Corrective Maintenance...................................................................................................12-6 Business Process: External Assignment as Individual Purchase Order.........................................................12-7 Business Process: External Company Work Centers.....................................................................................12-8 Business Process: External Services..............................................................................................................12-9 Business Process: Work Clearance Management........................................................................................12-10 Business Process: Preventive Maintenance with Cycle...............................................................................12-11 Business Process: Preventive Maintenance with Strategy...........................................................................12-12 Business Process: Refurbishment................................................................................................................12-13 Summary and Outlook: Integration of Plant Maintenance..........................................................................12-14 Integration of Plant Maintenance with Other Areas (1)...............................................................................12-15 Integration of Plant Maintenance with Other Areas (2)...............................................................................12-16 Summary and Outlook: Overview of Follow-Up Courses..........................................................................12-17 LO805 - Structuring and Managing Technical Objects...............................................................................12-18 LO810 - Preventive Maintenance and Service............................................................................................12-19 LO815 - Maintenance Processing: Operational Functions..........................................................................12-20 LO816 - Maintenance Processing: Controlling and Reporting...................................................................12-21 LO820 - Work Clearance Management (WCM).........................................................................................12-22 Summary and Outlook: Unit Summary.......................................................................................................12-23 Appendix............................................................................................................................................................13-1 Menu Paths and Transactions........................................................................................................................13-2 ASAP.............................................................................................................................................................13-6 ASAP: Business Scenario..............................................................................................................................13-7 ASAP: Objectives..........................................................................................................................................13-8 TeamSAP Components..................................................................................................................................13-9 AcceleratedSAP: Implementation Planning................................................................................................13-10 AcceleratedSAP Implementation Roadmap.................................................................................................13-11 Global ASAP...............................................................................................................................................13-12 IMG: Tasks...................................................................................................................................................13-13 Customer-Specific Configuration................................................................................................................13-14 Accelerated Industry Solutions: Steps.........................................................................................................13-15 Implementation Planning and Tools: Summary...........................................................................................13-16

0 LO100 Instandhaltung

LO100 Plant Maintenance 

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SAP AG 1999 2001 SAP AG

R/3 System Release 4.6C March 2001 Material number: 50042672

0.2 Copyright

Copyright 2001 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. All rights reserved.

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SAP AG 2001

Trademarks:  Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.  Microsoft®, WINDOWS®, NT®, EXCEL®, Word®, PowerPoint® and SQL Server® are registered trademarks of Microsoft Corporation.  IBM®, DB2®, OS/2®, DB2/6000®, Parallel Sysplex®, MVS/ESA®, RS/6000®, AIX®, S/390®, AS/400®, OS/390®, and OS/400® are registered trademarks of IBM Corporation.  ORACLE® is a registered trademark of ORACLE Corporation.  INFORMIX®-OnLine for SAP and INFORMIX® Dynamic ServerTM are registered trademarks of Informix Software Incorporated.  UNIX®, X/Open®, OSF/1®, and Motif® are registered trademarks of the Open Group.  HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C ®, World Wide Web Consortium, Massachusetts Institute of Technology.  JAVA® is a registered trademark of Sun Microsystems, Inc.  JAVASCRIPT® is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape.  SAP, SAP Logo, R/2, RIVA, R/3, ABAP, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.

0.3 Plant Maintenance (PM) Level 2

Level 3 LO805 3 days Structuring and Managing Technical Objects

LO975 3 days Document Management System

LO810 3 days Preventive Maintenance and Service

LO985

Plant Maintenance

LO815 3 days Maintenance Processing: Operational Functions

CA500 2 days The Cross Application Time Sheet (CATS)

AC020 Investment Management

LO816 3 days Maintenance Processing: Controlling and Reporting

LO100

Classification

5 days

2 days

LO820 3 days WCM Work Clearance Management

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3 days

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0.4 Course Prerequisites

 SAP20 - SAP R/3 Overview

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 Basic knowledge and experience of the business processes in Plant Maintenance

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0.5 Target Group

 Audience 

Project team managers

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Employees from the project team involved in modeling the business processes in Plant Maintenance

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Decision-makers responsible for selecting EDP-supported maintenance systems

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 Duration: 5 days

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1 Course Overview

 Course goal  Course content  Course overview diagram  Main business scenario

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1.2 Course Goal

This course will prepare you to:  Obtain an overview of Plant Maintenance  Recognize the most important business processes in Plant Maintenance  Perform analyses and evaluations  Understand the integration of Plant Maintenance with other SAP applications

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1.3 Course Content

Preface

Unit 1

Course Overview

Unit 7

External Services

Unit 2

Navigation

Unit 8

Unit 3

Organization of Plant Maintenance

Work Clearance Management

Unit 9

Preventive Maintenance

Unit 4

Technical Objects

Unit 10

Refurbishment

Unit 5

Breakdown Maintenance

Unit 11

Reporting and Analysis

Unit 6

Corrective Maintenance

Unit 12

Summary and Outlook

Appendix

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1.4 Course Overview Diagram

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Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook

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1.5 Main Business Scenario

 IDES AG performs the following types

of maintenance:  Breakdown maintenance  Corrective maintenance  External services  Preventive maintenance  Refurbishment of repairable

spares

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2 Navigation

Contents:  Navigation in the system  User-specific settings  Navigation in the mySAP.com Workplace

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2.2 Navigation: Unit Objectives

At the conclusion of this unit, you will be able to:  Identify the elements of a typical window  Navigate in the system  Personalize your user settings  Describe and use the mySAP.com Workplace

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2.3 Navigation: Business Scenario

 New users need to familiarize themselves with the screens in the system and define their personal default settings

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2.4 Logging On to the System User System

Help

SAP R/3 New Password

Client

If you have problems logging on,  contact Donna Moore, x486

User Password

Language

You can place your own text on the initial screen: See SAP Note 205487

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SAP R/3 Systems are client systems. The client concept enables the parallel operation, in one system, of several enterprises that are independent of each other in business terms. The components SAP Business Information Warehouse (BW) and SAP Knowledge Warehouse (KW) are exceptions to this: in these cases only one client is used. During each user session you can only access the data of the client selected during logon. A client is, in organizational terms, an independent unit in the system. Each client has its own data environment and therefore its own master data and transaction data, assigned user master records and charts of accounts, and specific Customizing parameters. For a user to log on to the system, a master record must exist in the system for that user. To protect access, a password is required for logon. The password is hidden as you type (you only see asterisks). SAP R/3 Systems are available in several languages. Use the Language input field to select the logon language for each session. Multiple logons are always logged in the system beginning with SAP R/3 4.6. This is for security as well as licensing reasons. A warning message appears if the same user attempts to log on twice or more. This message offers three options:  Continue with current logon and end any other logons of the same user in the system  Continue with current logon without ending any other logons in the system (logged in system)  Terminate current logon attempt You can place your own text on the initial screen in a number of ways. For more information, see the SAP Note mentioned above. The GuiXT (covered at the end of this chapter) offers a further option.

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2.5 SAP Easy Access - Standard Menu Edit Favorites Extras System

Help

SAP Easy Access Other Menu

Create Role

Assign User

Documentation

Favorites SAP Menu Office Logistics Accounting Human Resources Information Systems Tools

You are greeted by your logo in the right-hand part of the window.

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SAP Easy Access is the standard entry screen displayed after logon. You navigate through the system using a compact tree structure.

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You can include an image on the right-hand side of the screen such as your company logo. This image can only be entered systemwide, and is a cross-client setting. Assuming you have the appropriate authorization, you can find a detailed description of the necessary settings by choosing Extras  Administration Information. Note that this image is stored in the system and transported to the SAP Frontend every time it is called by SAP Easy Access. Although this transfer is compressed, the image for the initial screen should not be bigger than around 20 kB. You can prevent this image being called either by using the setting Low Speed Connection in the SAPLogon program (see SAP Note 161053), or by switching off the calling of the image under ExtrasSettings. See also UserSpecific Personalization.

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2.6 Role-Based User Menu Menu Edit Favorites Extras System

Help

SAP Easy Access - Enjoy User Menu Other Menu

Create Role

Favorites Great Transactions SM50 - Prcoess Overview VA01 - Create Sales Order Interesting WWW Pages URL - The Herald Tribune URL - Time Magazine Important Files URL - Vacation Planning Enjoy User Menu URL - SAP Notes (User / PW req.) Accounts Receivable FD02 - Change Customer (Accountin Materials Management Sales and Dsitribution Tools

Assign User

Documentation

Favorites chosen by the user reduce navigation time

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A Role describes a set of logically linked transactions in the system. These represent the range of functions users typically need for their work.

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User roles (previously “activity groups”) have to be set up using the Profile Generator so that SAP R/3 System users can work with user-specific or position-related menus.

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The authorizations for the activities listed in the menus are also assigned to the users using user roles. With Release 4.6, predefined user roles from all application areas are included in the standard system.

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Users who have been assigned a user role can choose between the user menu and the SAP standard menu.

The above screen shows the role-based user menu for a user with the name "Enjoy". You can find roles that are supplied in the standard SAP R/3 System by choosing Other menu on the SAP Easy Access initial screen.  Every enduser can personalize the initial screen using Favorites. You can create your own Favorites list containing the transactions, reports, files, and Web addresses that you use most often. 

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You can add favorites either by choosing Favorites or by using the mouse to “drag & drop” items into the Favorites directory.

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2.7 Screen Elements Command Field Menu Edit Favorites Extras System

Standard Toolbar

Help

System Function Name: Activity Choose

Save

Application Toolbar

Input field

Tick Selection 1 Selection 2 Selection 3 Selection 4

Checkboxes Radio Buttons Pushbuttons

Options Option 1 Option 2 Option 3

This screen is made up of various screen elements. It does not match an actual screen in the system. Overview

Option 4 Option 5

Positive Display

Edit

Neutral

Tab Page System Message

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Status Bar

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Command field: You can use the command field to go to applications directly by entering the transaction code. You can find the transaction code either in the SAP Easy Access menu tree (see the page User-Specific Personalization) or in the appropriate application by choosing SystemStatus.  Standard toolbar: The icons in the standard toolbar are available on all SAP R/3 screens. Any icons that you cannot use on a particular screen are dimmed. If you leave the cursor on an icon for a moment, a QuickInfo appears with the name (or function) of that icon. You will also see the corresponding function key. The application toolbar shows you which functions are available in the current application.  Checkboxes: Checkboxes allow you to select several options simultaneously within a group.  Radio buttons: Radio buttons allow you to select one option only.  Tabs: Tabs provide a clearer overview of several information screens.  Status bar: The status bar displays information on the current system status, for example, warnings or error messages. Other elements are: Menu bar: The menus shown here depend on which application you are working in. These menus contain cascading menu options. Title bar: The title bar displays your current position and activity in the system. 

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2.8 Selecting Functions ... using the transaction code in the command field Menu

Edit

Favorites

Extras

System

Help

Create session End session User profile SAP Easy Access - Enjoy User Menu Services Utilities List Favorites Services for object Enjoy User Menu Object history URL - SAP Notes (User / PW req.) Own spool requests Accounts Receivable Own Jobs FD02 -Change Customer (Account Short Message Materials Management Status... Sales and Distribution Log off

Tools

... using the menu path ... using SAP Easy Access and Favorites 

SAP AG 1999

You can select system functions in the following ways:  Use the mouse to choose: Menu options, Favorites, and SAP Easy Access options  Use the keyboard (ALT + the underlined letter of the relevant menu option)  Enter a transaction code in the command field: A transaction code is assigned to each function in SAP R/3 Systems. You can access the assigned transaction code from any screen in the system. For example, to display customer master data, enter /n and the appropriate transaction code (in this case /nfd03). You can find the transaction code for the function you are working in under the Status option of the System menu. Other possible entries: /n ends the current transaction. /i ends the current session. /osm04 creates a new session and goes to the transaction specified (SM04).  You can also use the keyboard to go to the command field. Use the CTRL + TAB key combination to move the cursor from one (input) field group to the next. Use TAB to move between fields within a group.  By entering search_sap_menu in the command field, you can search for and display the menu path for an SAP transaction. You can also search for text strings. 

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2.9 Field Help: F1 and F4 Customer

Edit Goto Extras Environment System

Help

Display Customer: Customer: Initial Screen

F1 Help: Displays the Meaning of Fields and Technical Information

Customer

Customer account number

Company Code

A unique key is used to clearly identify the customer within the SAP System. Procedure When creating a customer master record, the user either enters the account number of the customer or has the system determine the number when the record is saved, depending on the type of number assignment used. The account group determines how numbers are

Restrictions

assigned. Customer

1000

Entries Found

Company Code Company Name City Currency

Restrictions

F4 Help: Displays Possible Entries Co...

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Company Name City SAP A.G.

Restrict Number to

Cur...

IDES AG 1000

Walldorf EUR Frankfurt UNI

IDES Canada

Toronto CAD

IDES AG

Frankfurt UNI

SAP AG 1999

For help on fields, menus, functions, and messages, use F1. F1 help also provides technical information on the relevant field. This includes, for example, the parameter ID, which you can use to assign values for your user to input fields , which have to refer to these parameter IDs.  For information on what values you can enter, use F4. You can also access F4 help for a selected field using the button immediately to the right of that field.  If input fields are marked with a small icon with a checkmark, then you can only continue in that application by entering a permitted value. You can mark many fields in an application as either required entry fields or optional entry fields. You can also hide fields and preassign values using transaction or screen variants or Customizing.  

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2.10 Menus: System and Help Menu

Edit

Favorites

SAP Easy Access Other Menu

Favorites SAP Menu Office Logistics Accounting Personnel Information Systems Tools

Extras

System

Help

Create Session End Session User profile Rolle anlegen Services Utilities List Services for object Object history Own spool requests Own jobs

Application help SAP Library Glossary Benutzer zuordnen Release Notes SAPNet Feedback Settings...

Documentation

Short message Status... Log off

Both of these menus are available on every screen and always offer exactly the same options. T70 (1) (400)



iwdf5070 INS

SAP AG 1999

The System menu contains, among others, the following options:  Create/End Session: Allows you to create and end sessions. The maximum number of sessions can be set to a number between 2 and 6 by the system administrator using the parameter rdisp/max_alt_modes.  User profile: This is where you can enter user-specific settings. For example, you can use Parameter IDs in Own Data, in order to set default values for specific user-dependent fields in the system (for example the company code field).  List: Contains important list functions, such as searching for character strings, saving in PC files, printing, and so on.  Status: Enables you to display important user and system data.  Log off: Ends the R/3 session with a confirmation prompt.  The Help menu contains, among others, the following options:  Context-sensitive Application Help  Access to the SAP Library (see previous page)  a Glossary  ... 

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2.11 SAP Library SAP Library - SAP Library

Contents

Index

Search

SAPLibrary

SAP Library Release 4.6C, March 2000

IDES Getting Started

You can access the complete online documentation for the system using the SAP Library

Release Notes Implementation Guide Glossary 

Copyright 2000 SAP AG All rights reserved.



SAP AG 1999

SAP R/3 Systems provide comprehensive online help. You can display the help from any screen in the system. You can always request help using the Help menu or using the relevant icon (the yellow question mark).  You can access the SAP Library quickly and comfortably by using the SAP Service Marketplace. There you can find the SAP Help Portal under Knowledge and Training, where you can not only access Help in HTML format, but can also perform efficient full-text searches in the SAP Library. If you have the SAP Library installed, you also have, of course, these opportunities within your company.  You can access the Help Portal directly at http://help.sap.com 

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2.12 User-Specific Personalization Menu

Edit

Favorites

SAP Easy Access Other Menu

Favorites SAP Menu Office Logistics Accounting Human Resources Information Systems Tools

Exrtas

System

Help

Administration Information Ctrl+Shift+ F8 Assign user Options ... Display Documentation Shift+ F6 Generate Graphic Rolle anlegen zuordnen Dokumentation Ctrl+Shift+Benutzer F10 Technical Details Create Shortcut ... Shift+ F9 Settings Activate GuiXT Set Start Transaction Shift+ F7 Default Size Hardcopy Quick Cut and Paste About...

Settings This is used to specify settings Display favorites at end of list Do not display menu, only display favorites Do not display picture Display technical names

Different Settings options make working with the system easier T70 (1) (400)





iwdf5070 INS

SAP AG 1999

The end user has many possibilities for personalizing the system. Some are described below:  You can alter the layout of your initial screen under Extras  Settings, for example by switching off the image in the right-hand part of the window or by turning on the option to display the technical names (transaction codes) in the SAP Easy Access Menu.  Among other things, you can activate a quick cut and paste in the Options menu. Using Options you can change the reaction speed of the QuickInfo that is displayed when you hold your mouse cursor over an icon or a push button.  By following the path System User profile Own data, you can set personal standard values. You can choose the tabs Address, Defaults, and Parameters. As an example, the setting of Parameters is explained here: Parameters: Here you can set defaults for frequently used input fields. In order to be able set a default value for a field, it must have been assigned a Parameter ID. Procedure for finding the Parameter ID: Go to the field for which you wish to set a default value. Select the F1 help, and then choose Technical Info. The system displays an information window that contains the relevant parameter ID under the heading Field Data (as long as the field has been assigned a Parameter ID).

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2.13 Personalizing the Frontend with GuiXT

FD03 without GuiXT

FD03 with GuiXT

Example from http://www.guixt.com 

SAP AG 1999

SAP R/3 Systems offer numerous options for settings and adjustments:  Define default values for input fields  Hide screen elements  Deactivate screen elements (dimmed) You can do this by, for example, defining transaction variants.  SAP offers GuiXT, as of SAP R/3 Release 4.6. In addition to all of the above functions, you can now:  Include graphics  Convert fields and add pushbuttons and text  Change input fields (or their F4 help results) into radio buttons  GuiXT scripts are stored on the Frontend. In accordance with local scripts (which can also be stored centrally), the GUIXT scripts determine how data sent from the application server is displayed. These scripts can be standard throughout a company, or they can be different for each Frontend.  NOTE: The GuiXT will support the mySAP.com Workplace only as of the end of the year 2000. This means that until then you should use either the SAP GUI for the Windows Environment and the GuiXT or the mySAP.com Workplace with the SAP GUI for HTML (or the SAP GUI for Java or the SAP GUI for Windows). 

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2.14 Elements of the Workplace

In Use

mySAP.com-Marktplatz Aktualisieren Anpassen Log off from the Workplace Willkommen Willi Workplace Expand/Collapse LaunchPad

Getting Started

Info

Web Search

Start Page

Search

Workplace Favorites Roles Demonstration Role

LaunchPad

in

Start Search

WorkSpace (MiniApps, Transactions, & Web Pages)

Drag&Relate 

 

SAP AG 1999

The graphic above shows Release 2.11 of the mySAP.com Workplace. You call the mySAP.com Workplace by entering the relevant URL (Internet address) in a Web Browser. Usually this is done by clicking a link (instead of being entered manually). The syntax for the URL of the Workplace is typically ://[:]/scripts/wgate/sapwp/!, for example: https://workplace.wdf.sap-ag.de:1042/scripts/wgate/sapwp/!

The ! is an essential part of the call.  The browser window of the mySAP.com Workplace consists of three areas:  When working with the mySAP.com Workplace, the roles containing the entries relevant to your job appear in the LaunchPad. You can also add your own entries (Favorites) to the LaunchPad.  When you log on to the mySAP.com Workplace, the list of MiniApps (for example: the StockTicker, news, overview lists, or reports) that are assigned to your role appears in the WorkSpace on the right-hand side, as well as MiniApps that you have added yourself. If you start a particular transaction in the LaunchPad (for example, the transaction for booking invoices), this application is executed in the WorkSpace on the right-hand side.  Session handling in the Workplace allows you to hold several applications at the same time in channels. The individual channels are displayed as icons in the In Use folder. By clicking on the entries, you can switch between the different applications.  Using Drag&Relate you can link objects from one application with another with a simple mouse click and execute them from there.

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2.15 Active Applications (In Use) mySAP.com Marketplace

Update

Personalize

Getting Started

Info

Welcome Julie Armstrong In Use

Web Search

Start Page

Personalize

Search

Workplace Favorites Roles Demonstration Role

Workplace Favorites

Start Page

Start Search

General

Optionen

Initial Screen (MiniApps)

in

Change Role Sequence

Allow More Than One Application in the Area “In Use“ (Requires Restart of the Workplace)

Test

Close Applications Without Confirmation Display Dialog for Drag&Relate

Standardsprache der Komponentensysteme

Activate Session Handling

Language (for all Systems)

Logonlanguage

Client QW2/050

Logon language

OK



Cancel

SAP AG 1999

The In Use area:  You can manage multiple windows (Workplace Views) oin this folder in the LaunchPad. You can switch from one Workspace View to another without affecting the applications that you are running.  To be able to operate multiple Channels at the same time, you must change your personal settings for the Workplace. Choose Personalize, and then the General tab. In the Options sections, check the option Allow More Than One Application in the Area “In Use”. After this is activated, multiple parallel channels are available.  In the example above, only the Start Page (“Home”) is shown in use, with an illustration of its assigned MiniApps.

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2.16 Workplace Favorites mySAP.com Marketplace

Update

Personalize

Getting Started

Info

Welcome Julie Armstrong In Use

Web Search

Start Page

Search

Workplace Favorites Roles Demonstration Role

Start Search

in

Add Favorites using Drag&Drop or Personalize Workplace Favorites

Start Page

General Attributes

Workplace Favorites Favorite Transactions WWW Addresses Time Magazine International Herald Tribune

Apply

Available in Roles

Web Address http://help.sap.com Name

Online Documentation

New Web Address Test

New Folder

Display in a separate browser window

Test Web Pages and Add them to the Favorites List Delete OK



Cancel

SAP AG 1999

You can personalize the LaunchPad using Favorites. By choosing Personalize (or by choosing the Personalize icon), you open a new window. You can create and (re)name your own folders in the left-hand part of the tab page Favorites, as well as moving them and changing their grouping.  You can enter Web addresses (URLs) in the right-hand part. These are then available in the Favorites folder in the LaunchPad. You should test your favorites by choosing the Test button before you add them to your favorites list. A favorite that requires a complete browser window is not suitable for displaying in the WorkSpace of the mySAP.com Workplace.  



You can see the entries in your LaunchPad that were assigned to you by your system administrator on the second tab page, Available in Roles. This contains, for example, transactions. If you use a transaction frequently, you can define this as a favorite. To do so, click the relevant transaction and choose Add.



You can also add to and edit your favorites directly form the LauchPad. Using Drag&Drop, you can add frequently used transactions to the Favorites folder.

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2.17 Personalizing MiniApps mySAP.com Marketplace

Update

Personalize

Getting Started

Info

Welcome Julie Armstrong In Use

Web Search

Start Page

Search

Workplace Favorites Roles Demonstration Role

Workplace Favorites

Start Page

General

Displayed in Work Area List View ZCALCULATOR

Start Search

in

Attributes

Layout Preview

Available MiniApps

Web Address http://www.sap.com/MiniApps Apply

Web Search

Name

MiniApp Community

Height

10

New MiniApp

Lines

Minimized

Test

Reuters News

Hide OK





 





Cancel

SAP AG 1999

MiniApps are Web applications or documents that are simple and intuitive to operate. After you have started the mySAP.com Workplace, they offer you a quick overview and access to the functions that are most important to you on the initial screen. You are assigned the MiniApps in the Workspace by your system administrator, but you can also add your own MiniApps. By choosing the menu option Personalize (or alternatively by choosing the Personalize icon), you open a new window. You can add your own MiniApps on the right-hand side of the tab page Start Page under New MiniApps. Also enter the Web address (URL), a name for the MiniApp, and the height in lines. Test MiniApps before adding them. You can easily rename and reassign them later. You can change and adjust the format of MiniApps. On the tab page MiniApps, you can change the order in which the MiniApps are displayed on the Workplace or choose your desired display format (minimized or expanded). Take note of the address http://www.sap.com/miniapps. This is the homepage of the MiniApp community. Here, you can find current information about available MiniApps in SAP systems and about Internet services that you can add to those available in your Workplace.

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2.18 Workplace: Advantages

User

Enterprise  Low Total Costs

 User-Friendliness Role-based access  Tailored to match your needs  Access from anywhere 

 Efficiency

No installation expenses at the PC workstation  Standardization  Uncomplicated maintenance 

 Security

“Drag&Relate”  Uniform access  Log on only once 

Central administration  Controlled access 

 Productivity

 Openness Standard Internet user interface  Components from SAP and other providers  Extendable role specifications 





SAP AG 1999

Both the user and the enterprise profit from the advantages of the mySAP.com Workplace.

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2.19 Navigation: Unit Summary

You are now able to:  Identify the elements of a typical window  Navigate in the system  Make personal system settings  Describe and use the mySAP.com Workplace



SAP AG 1999

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2.20Navigation - Exercises Unit: Navigation Topic: Basic Functions At the conclusion of this exercise, you will be able to: 

Log on to an SAP R/3 System



Find transaction codes



Access the SAP Library



Use F1 help to find field information



Use F4 help to search for possible field entries

As a new user of an SAP R/3 System, you begin to navigate the system using the menu paths and transaction codes. You also begin to access the various types of online help.

All menu paths in the exercises refer to the SAP standard menu. 1-1

Logging on to the system Select the appropriate system for this course. Use the client, user name, initial password and logon language specified by the instructor. The first time you log on, you will get a prompt in which you must enter your new password, which you choose yourself, twice. Make a note of the following: Client: _ _ _ User: _ _ _ _ _ _ Password: ____________ Language: _ _.

1-2

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What is the maximum number of sessions (windows in the SAP R/3 System) you can have open simultaneously? __

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1-3

Identify the functions and find the transaction codes that correspond to the following menu paths in the SAP standard menu. 1-3-1 Tools Administration  Monitor  System Monitoring User Overview Name of function: ___________________________________________ Transaction: _________________________________________________ 1-3-2 Accounting  Financial Accounting  Accounts Receivable Master Records Display Enter Customer 1000 and Company Code 1000 to go to the next screen.

Name of function: _____________________________________ Transaction: ___________________________________________

1-4

Help 1-4-1 If you choose Application help in the SAP Easy Access initial screen (System menu), which area of the SAP Library does it take you to? _________________________________________________________

To answer the questions below, you will need to go to the Display Customer: Initial Screen. 1-4-2 Use F1 help on the Customer field. What is this field used for? Write a brief summary of the business-related information. ______________________________________________________

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1-4-3 Use the F1 help on the Company code field. If you choose the Application help icon from the F1 help screen, which area of the SAP Library does it take you to? ______________________________________________________ 1-4-4 Which icon do you need to use on the F1 help screen to find the parameter ID for the Company code field? Hint: See the notes on the slide User-Specific Personalization

______________________________________________________ 1-4-5 Use F4 help on the Customer field to find the customer number for Becker ##. To do this, use the Search term "Becker*" after calling the F4 help. Note: ## corresponds to your assigned group number. ___________________________________________________

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Unit: Navigation Topic: User-Specific Settings At the conclusion of this exercise, you will be able to: 

Set a user parameter for a field



Set user defaults



Maintain your favorites



Select a start transaction of your choice

You begin to set various user-specific settings.

Exercises marked * are optional. 2-1

Setting user parameters. 2-1-1 Assign a parameter value for the Company code field to your user profile. Note: The instructor will tell you what parameter value to enter (for example 1000). For information about defaults, see the notes on the slide UserSpecific Personalization. Parameter ID: ___ ___ ___ Parameter value: ___ ___ ___ ___

2-2

Defining User-Specific Settings using System  User profile  Own Data 2-2-1 In your user profile, set your logon language to the value used for the course. 2-2-2 In your user profile, set the decimal notation and date format of your choice.

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2-3

Defining your favorites 2-3-1 Insert at least one new folder under the Favorites folder. 2-3-2 Add any two of your favorite transactions to the corresponding folders. 2-3-3 Add the Internet address http://www.sap.com with the text SAP Homepage.

2-4*

Setting a start transaction using the Extras menu. 2-4-1 Enter a transaction of your choice as the initial transaction. You will then need to log off and on again for the change to take effect. Note: If desired, you can change the initial transaction back to the default value simply by deleting the transaction code that you entered.

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2.21Navigation - Solutions Unit: Navigation Topic: Basic Functions

1-1

Log on to the system specified by the instructor and change your initial password.

1-2

To open and close sessions, choose System  Create session (or use the appropriate icon) or System  End session. The maximum number of sessions you can have open simultaneously is six (6), depending on your system settings.

1-3

To find the transaction code, choose System  Status. These function names and transaction codes correspond to the menu paths: 1-3-1 Transaction: SM04 for Function Name: User list 1-3-2 Transaction: FD03 for Function Name: Display Customer: General Data

1-4

Help 1-4-1 The section of the unit Getting Started that deals with using SAP Easy Access is displayed. 1-4-2 Suggestion: The customer is a unique key (account number) used to clearly identify the customer within the system. 1-4-3 FI – Accounts Receivable and Accounts Payable 1-4-4 To find the Parameter ID: BUK, choose Technical Info 1-4-5 Customer ## (## corresponds to your assigned group number) When you select F4 in the Customer field, the Restrict Value Range window appears. You can explore the various tabs to see the different search criteria available. Find a tab that includes the Search term field and enter the following: Field Name

Value

Search term

Becker*

Choose Enter. A window appears listing the customer account numbers that match your search criteria. Select the line that corresponds to Becker ##, then choose Copy. This automatically copies the customer account number into the Customer field.

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Unit: Navigation Topic: User-Specific Settings

2-1

Setting user parameters. 2-1-1 To assign a parameter value to a field you will need the parameter ID of the field. First you need to select a transaction that contains this field. For example, Company code can be found in transaction FD03. Next, place the cursor on that field (click it with the mouse). To display the required info, choose: F1  Technical Info  Parameter ID gives you the required information. For the Company code field, the parameter ID is BUK. Finally, enter the parameter ID and desired value in your user profile: System  User profile  Own data On the Parameter tab page you enter the parameter ID and value that you want to be entered into the field. Save your entries.

2-2

Setting user defaults. 2-2-1 To set the logon language, go to your user profile: System  User profile  Own data On the Defaults tab page, enter the language of your choice in the Logon language field. 2-2-2 To set the decimal notation and date format, remain on the Defaults tab in your user profile. Select the indicator adjacent to the notation and format you desire. Save your selections.

2-3

Defining favorites of your choice. 2-3-1 Favorites  Insert folder Type any name for the folder then select Enter. You can add as many folders as you desire. Once created, folders can be dragged and dropped to position them where you want. 2-3-2 To create favorites, select specific applications (transactions) that you need as favorites for your daily work from the menu tree of the SAP standard menu. Add them to your Favorites list by selecting them and choosing Favorites  Add from the menu bar. Alternatively, use the mouse to drag & drop favorites to a folder. You can also use the menu path Favorites  Insert transaction to add using a transaction code.. Finally, you can move existing favorites to different folders later by choosing Favorites  Move or using drag & drop.

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2-3-3 Create Internet addresses by choosing Favorites  Add Web address or file. When you select SAP Homepage from your favorites, an Internet browser will open and you will be connected to SAP’s homepage. 2-4

Setting a start transaction. 2-4-1 Extras  Set start transaction Enter a transaction of your choice then choose Enter. Notice the system message on the status bar indicates that your selected transaction has been set as the start transaction. The next time you log on, the system will go directly to your start transaction. Note: To change back to SAP Easy Access as the initial screen, follow the menu path again, delete the transaction code and select Enter. The next time you log on, SAP Easy Access will be the initial screen.

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3 Organization of Plant Maintenance

Contents  General considerations  Plant Maintenance organizational structures



SAP AG 2001

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3.2 Organization of Plant Maintenance: Unit Objectives

At the conclusion of this unit, you will be able to:  List the different types of maintenance  Describe how Plant Maintenance is structured  List the organizational units relevant to Plant Maintenance



SAP AG 2001

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3.3 Course Overview Diagram



Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook

SAP AG 2001

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3.4 Organization of Plant Maintenance: Business Scenario

 Plant Maintenance is an integral part of the company and has numerous links to other enterprise areas.  Depending on the company structure, maintenance planning is either plant-based (decentralized) or cross-plant (centralized).



SAP AG 2001

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3.5 Organization of Plant Maintenance: General Considerations

 General considerations  Plant Maintenance organizational structures



SAP AG 2001

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3.6 Types of Maintenance

Tool assembly

DIN 31051

Inspection Modification

Cleaning Preventive maintenance

To determine the actual condition of an object

To maintain the target condition of an object

Refurbishment

Repair To restore the target condition of an object

Construction

Production assistance

........ 

SAP AG 2001

Maintenance of a technical system comprises the following tasks: Inspection: To determine the actual condition Preventive maintenance: To maintain the target condition Repair: To restore the target condition  The maintenance organizations usually perform other technical activities. which do not belong to Plant Maintenance, but should be performed using the same tools of maintenance order planning and processing, for example: Modification or construction Cleaning Revisions Tool assembly and erection of fixtures Production assistance Etc. 

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3.7 Product Lifecycle Management (PLM) Design

Sales and Production

Service

Customer Relationship Management

Production Lifecycle Management

Product idea 

Supply Chain Management

End of production

Start of production

Product phase-out

SAP AG 2001

Product Lifecycle Management (PLM) views the lifespan of a product from a manufacturers' perspective.  Plant maintenance and service represent the final phase of a product's lifespan. 

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3.8 Asset Life-Cycle Management (ALM)

SStru tructu c turin ringg ooff te c hhnnic tem ss tec icaall ssyysstem

CCAAxx GGIS IS

Investment idea 

PPreven re ventive tiv e m ncce e main ainten tenaan

In Intern ternet et nnootificatio tificationnss

O Ord rdeerr && nnootific atio nnss tificatio

End of operation

Start of operation

SSoolu lutio tionn ddatab atabase as e

Replace

SAP AG 2001

Asset Life-Cycle Management (ALM) views the life-span of a technical system from the perspective of the company operating it.  Plant maintenance and service are integral components of ALM.  ALM combines the SAP R/3 components PM, QM, and CS. 

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3.9 Plant Maintenance Integration

Materials Management

Production

Joint Venture

Controlling Project Management

Plant Maintenance

Financial Accounting

HR System

Investment Management

Funds Management

Asset Accounting



 

Real Estate Management

SAP AG 2001

The PLM/ALM component Plant Maintenance is extremely well integrated. The following courses provide information on integration: - Materials Management, Controlling, Financial Accounting in this course - Asset Accounting in Course LO805 - Production and HR System in Course LO815 - Investment and Project Management in Course LO816 - Real Estate Management in Course AC290 - Funds Management in Course AC700 - Joint Venture is part of the Industry Solution IS-Oil and must be installed separately. Integration with the standard system is planned. You can find information about these components in SAPNet.

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3.10 Organization of Plant Maintenance: Plant Maintenance Organizational Structures

 General considerations  Plant Maintenance organizational structures



SAP AG 2001

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3.11 Organizational Structures in Plant Maintenance General Organizational Units in Logistics Client Company code Plant Location-Based Organizational Units Maintenance plant Location Plant section

For example, site, building, coordinate For example, production area, plant engineer

Planning-Based Organizational Units Planning plant



Maintenance planner groups Maintenance Work Centers

For example, foreman, work scheduling For example, mechanics

SAP AG 2001

The client is the highest-level element of all the organizational units. It corresponds, for example, to a corporate group with several subsidiaries. Within a client, the system always accesses the same database. The subsidiaries with their own financial statements and balance sheets are defined as company codes. Within Logistics, the plant is one of the most important organizational units. It usually represents a production unit of a company.  The plant, at which the operational systems of a company are installed, is called the maintenance plant. If the maintenance work is planned at this plant, the maintenance plant is also the maintenance planning plant. Locations subdivide a maintenance plant according to locational criteria, for example, site, building, coordinates. A maintenance plant can also be subdivided into plant sections based on responsibility for production. The person responsible for the plant section is the contact person who coordinates production and maintenance (plant engineer).  A maintenance planning plant is the organizational unit in which maintenance requirements are planned. These requirements can either come from your own plant or from another maintenance plant assigned to this maintenance planning plant. The planners within a maintenance planning plant are defined by maintenance planner groups. The units of capacity in Plant Maintenance are managed as maintenance work centers in the PM system. The maintenance work centers are usually assigned to the maintenance planning plant. However, you can also use maintenance work centers from other plants to perform maintenance tasks. 

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3.12 Cross-Plant Maintenance

Plant Plant 1200 1200

Plant Plant 1300 1300

Maintenance requirement

Maintenance requirement Workshops

Warehouse

Plant Plant 10001000 Planning of maintenance requirements

Maintenance requirement

Workshops Material 

SAP AG 2001

Maintenance plant = planning plant: In most organizational structures, the maintenance requirement is planned in the same plant where it occurs (plant 1000), the maintenance orders are executed by workshops from the same plant, and the spare parts are stored in the same plant.  Maintenance plant: Maintenance is required at plant 1200, where a technical system must be repaired (= maintenance plant), but all other functions (maintenance planning, order execution, spare parts warehouse) are performed by plant 1000. Alternatively, part (order execution) of the maintenance required is performed at plant 1300, but other functions (order planning, spare parts storage) are performed by other plants.  The latter is cross-plant maintenance. 

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3.13 Roles in Plant Maintenance

Maintenance planner Nicole Potter

Maintenance manager James Taylor 

  

   

Maintenance supervisor Scott Weiland

Maintenance engineer Harry Meyers

Technician Kate Stevens

Work clearance planner James Cameron

SAP AG 2001

You can gain access to plant maintenance transactions in the general SAP menu, or via a rolespecific menu designed around the duties of a specific employee. The following five example roles are available in the standard system for Plant Maintenance: Maintenance planner Deals with and monitors malfunctions and requirements, plans and monitors maintenance orders. Different people may assume the role of maintenance planner depending on the organization (for example, centralized or decentralized planning). Maintenance supervisor Responsible for a workshop/work center and the processing of maintenance orders in his area. Maintenance technician Carries out maintenance orders. Maintenance engineer Responsible for the mapping and preventive maintenance of technical systems. Maintenance manager Responsible for the overall maintenance process, prepares budgets and monitors cost/damage trends.

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3.14 Role Functions

Employee Leave request

Maintenance engineer Processing equipment

Collective role

SAP user Harry Meyers

Single role

Collective role

Single role

Create equipment Change equipment

Harry Meyer's user menu

Change list editing ...

Leave request

Single role

Processing equipment ...



SAP AG 2001

When a role is assigned to a user, transactions required for functions appear automatically in the user menu. This menu appears automatically when the user logs on. Each example role can be easily copied and then adapted to individual requirements.  The example roles are available in the form of Collective roles. Each collective role includes a number of Single roles. Each single role contains a group of related transactions.  You assign one or more collective roles to an SAP user. The collective roles assigned to a user form the user menu.  Example: Harry Meyers works as a maintenance engineer for IDES AG. His role as employee means that he needs access to general functions, for example, making a leave request. In his role as maintenance engineer he manages technical objects. The collective roles Employee and Maintenance engineer are assigned to his SAP user profile, and his user menu is then available. 

(C) SAP AG

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3.15 Single Roles

Single role

Collective role

Processing equipment

Maintenance engineer

Create equipment Change equipment Change list editing

Maintenance planner

Single roles can be assigned to multiple collective roles



Customer defined role

SAP AG 2001

A single role contains a series of similar transactions. Predefined single roles for each application component are available in the standard system.  Each single role can be used in any number of collective roles.  At the present time, the roles in Work Clearance Management are available only as single roles. 

(C) SAP AG

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3.16 Maintenance Work Centers

For example: Welding Metalworking Mechanics





SAP AG 2001

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. 

(C) SAP AG

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3.17 Work Center: Contents

 Basic data 

General data

 Capacity data  

 Capacity / pool capacity

Capacity categories Scheduling





Links

      



Available capacity profile

Activity types

Activity types

Activity types Cost center Work center Person Qualification Staffing assignment

Time

SAP AG 2001

The basic data contains general data such as work center category, description, responsibility, and usage.  Work center links provide the connection between work centers and other objects within the SAP System. You can link a work center to the following objects: - Cost center - Qualifications - Staffing positions - People  The links are valid for certain periods of time. 

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3.18 Work Center: Main Functions Work Work center center

Default Default values values for for task task lists lists and and orders orders

Costing Costing data data

Scheduling Scheduling data data and and available available capacity capacity

Task Task list/order list/order

Costing Costing

Lead Lead time time scheduling scheduling Capacity Capacity planning planning

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

SAP AG 2001

Costing: You can use costing to determine the costs of an internal activity by a product unit. The aim of costing is to attribute the costs incurred to the individual cost objects. It uses the work center to link the operation to cost accounting by maintaining cost centers and activity types. If the work center is used in an operation, standard values can be entered for the activity types specified in the work center.  Scheduling: You can use scheduling to determine the dates when operations should be performed. For this, the time required for the operations must be calculated and compared with the time available in the work center. The standard values and quantities in the operations are used as the basis for this calculation. During scheduling, the start and end dates for the operations are calculated from this data using formulas, which have been entered for scheduling in the work centers.  Capacity planning: In capacity planning, the capacity requirements for the operations in the orders are determined and compared with the available capacity defined in the work center. During capacity planning, you can use work center hierarchies to aggregate (at higher-level work centers) the available capacity and capacity requirements of lower-level work centers. 

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3.19 Organization of Plant Maintenance: Summary

You are now able to:  Describe the different types of maintenance and the structure of Plant Maintenance  List the general and maintenance-specific organizational structures



SAP AG 2001

(C) SAP AG

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3.20Exercises Unit: Organization of Plant Maintenance Topic: Organizational Structures in Plant Maintenance At the conclusion of these exercises, you will be able to:  Describe the content of the work center master record  List the organizational structures in Plant Maintenance

At IDES, it must be clarified when PM is implemented which organizational structures in Plant Maintenance should be represented, and how they should be included in the existing structures for Logistics.

Data Used in the PM Courses:

Description

Training System

IDES

General Controlling area

1000

1000

Company code

1000

1000

Plant

1000

1000

Storage location

0001

0001

Purchasing organization

1000

1000

G/L account

417000

417000

Vendors

1000, 1101, 1102

1000

SRV-1 Technical Objects Equipment

TEQ-##

P-1000-N001

Inspection equipment

10003540,

10003540,

10003541

10003541

Equipment with equipment BOM (C) SAP AG

T-SM0100 – T-SM0120

LO100

20

Configurable equipment Functional locations

P-6000-N001

P-6000-N001

C1

C1

## (*)

SERV-PRO-RZ-##

SERV-PRO-RZ-## Operating hours counter for

Created during course

FL -> C1-M01-2, C1-M013, C1-M02-2, C1-M02-3 Status profile for equipment PMSTAT Materials and Bills of Material Materials: Pump without serial number - standard price for batch

T-FP1##

P-2001

Pump with serial number standard price for batch

T-FP2##

P-2002

Pump with serial number moving average price for batch

T-FP3##

P-2003

Pump without serial number - moving average price for batch

T-FP9##

P-2009

Material with conditionbased valuation (standard price valuation)

P-2001

P-2001

Serial number profile

PM1

PM1

Configurable material

P-6000

Not available

Bill of material for material P-6000

P-6000

Not available

(stock check = 1 > warning)

Materials for material BOM 100-100 P-1000 100-400 (plant 1000, link 4) DG-1000

(C) SAP AG

100-100 100-400 DG-1000

100-600

100-600

100-431

100-431

KR117185

KR117185

WL-1000

WL-1000

G-1000

G-1000 LO100

21

M-1000

M-1000

Materials for equipment BOM

DPC9021

DPC9021

C-1112

C-1112

T-SM0100 – T-SM0120

R-1120

R-1120

(plant 1200, link 4)

R-1131

R-1131

R-1160

R-1160

Configurable material (service)

INSPECTION_SERVI CE Work Centers

Work centers

T-ME##

Mechanics

T-EL##

Electrics

T-EX## Task Lists and Maintenance Planning PUMP_WTG

PUMP_WTG

PUMP_REP

PUMP_REP

MM-CALIB

MM-CALIB

Profile

0000001

0000001

Maintenance plans

50

50

Service procurement

600000000000

600000000000

PM/QM link

51, 52

51, 52

Performance-based maintenance strategy

DFL

DFL

Cycle set

ZS

ZS

Configurable general task list for WPL in connection with configurable equipment

PUMP_WTG 6

PUMP_WTG 6

Task lists

(old status)

Maintenance plan with Maintenance plan 80 configurable equipment and configurable general task list Notification and Order Processing Service masters

100131, 100132

100131, 100132

Order type for generating inspection lot

PM06

PM06

Control key for internal processing of service

PM05

PM05

Standard text keys

PM00001 - PM00008

PM00001 - PM00008

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Settlement profile for refurbishment (for order type PM04)

PM_AWA

Order type for investment orders

PM07

Service masters for internal service processing (control key PM05)

100020, 100021

Cost Centers and Activity Types Cost centers Installation of

4300

4300

technical systems

4110

4110

for external company

4350

4350

Activity types

1410 (rep. hrs)

1410 (rep. hrs)

1610 (external hrs)

1610 (external hrs)

Allocation cost element for activity type 1610 Outline Agreements / Framework Orders Outline agreements Pipe laying work (vendor 1102)

4600000023

Services (vendor 1101)

4600000024

Framework order for services

4500007351

4600000024 (pipe laying, vendor 1101)

Service Maintenance contract

40000077

Configurable material (service)

INSPECTION_SERVI CE

Sold-to party

1171 Classes

Variant class (used in CL_P600 configurable equipment and configurable general task list

CL_P600

Project and Investment Program Project

I/5001

I/5001

Project profile

PM00001

PM00001

Investment program

PM2000

Not available

(C) SAP AG

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(C) SAP AG

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1

Displaying Work Center Master Data Display the work center T-ME## in plant 1000. Which menu path do you use? ____________________________________________________________ Determine the following data: Person responsible for work center: ________________________________ Task list usage:

Which task list types are permitted by the task list usage? _________________________________ Operating time/capacity:

Cost center:

Activity type, internal processing:

2

Right or Wrong A maintenance plant can also be a maintenance planning plant. ____________________________________________________________ A location (for example, building F-141) can only exist once within the company. ____________________________________________________________ A maintenance planner group is assigned to a maintenance planning plant. ____________________________________________________________ A maintenance plant is assigned to a maintenance planning plant. ____________________________________________________________

(C) SAP AG

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3.21Solutions Unit: Organization of Plant Maintenance Topic: Organizational Structures in Plant Maintenance

1

Displaying Work Center Master Data SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Environment  Work Centers  Work Center  Display

2

Field name or data type Person responsible for work center

Values 101

Task list usage

004

Task list types

Maintenance/service task lists

Operating time/capacity

7.20 h/36.00h

Cost center

4300

Activity type, internal processing

1410

Right or Wrong A maintenance plant can be a planning plant Right A location (for example, building F-141) can only exist once within the company. Wrong (a location is related to a plant) A maintenance planner group is assigned to a maintenance planning plant. Right A maintenance plant is assigned to a maintenance planning plant. Right

(C) SAP AG

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4 Technical Objects

Contents:  Functional locations  Equipment  Bills of material



SAP AG 1999

(C) SAP AG

LO100

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4.2 Technical Objects: Unit Objectives

At the conclusion of this unit, you will be able to:  Describe the concept and criteria for functional locations  Describe the concept and criteria for equipment  Create a piece of equipment  Describe the application of bills of material in Plant Maintenance



SAP AG 1999

(C) SAP AG

LO100

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4.3 Course Overview Diagram



Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook

SAP AG 2001

(C) SAP AG

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4.4 Technical Objects: Business Scenario

 For IDES you first need to decide which technical systems and buildings are relevant for maintenance and need mapping in PM.  Use functional locations to map more complex technical systems, equipment to map individual objects, and maintenance bills of material to map spare parts.  In IDES, maintenance engineers are responsible for technical structures.



SAP AG 2001

(C) SAP AG

LO100

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4.5 Technical Objects: Phases and Roles

Phase

1

Identification

2

Structuring

3

Classification



Contents

Roles

Which objects are relevant to Plant Maintenance?

Maintenance engineer

Which objects are mapped?

Maintenance engineer

Which object classes with which technical data?

Maintenance engineer

SAP AG 2001

When starting to map technical objects you need to decide which objects are relevant to Plant Maintenance - in other words, which objects require maintenance measures and for which objects evaluation is required (Phase 1 - Identification).  In the second step you choose the structuring instruments for each object (functional location, equipment, assembly, material), and create the structure (Phase 2 - Structuring).  In the third step you create characteristics (= technical characteristics - for example, electrical output) and classes (for example, pump classes). All technical characteristics become available for an object when a technical object (for example, equipment) is assigned to a class. (Phase 3 Classification).  Note: Classification is dealt with in the level three course LO805 - Management of Technical Objects. 

(C) SAP AG

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4.6 Technical Objects: Functional Locations

 Functional locations  Equipment  Bills of material



SAP AG 1999

(C) SAP AG

LO100

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4.7 Functional Location Functional location = multi-level, hierarchical structure, organized according to ...

Spatial

Technical

Functional

Criteria 

SAP AG 1999

Functional locations are hierarchically ordered structures that represent a technical system, building, or part thereof.  You can structure the functional location according to spatial (for example, building 1, building 2), technical (for example, press, press frame, press hydraulics), or functional, that is, process-oriented criteria (for example, polymerization, condensation).  The aim of creating a functional location is to structure a technical system or building into units that are relevant for Plant Maintenance. 

(C) SAP AG

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4.8 Criteria for Functional Locations

For what purpose is a functional location created?     





Execution of maintenance tasks Recording of maintenance tasks Data collection over long periods of time Cost monitoring by area What affect do the usage conditions have on the likelihood of damage to the installed aggregates?

SAP AG 1999

You should use functional locations to structure your systems if:  You want to represent the structures of the technical systems in your company according to functional criteria  Maintenance tasks have to be performed for individual areas in the structure of your technical system and this work must or should be recorded  Technical data for certain parts of your technical system has to be stored and evaluated over a long period of time  The costs of maintenance tasks have to be monitored for certain parts of your technical system  You want to analyze what effects the usage conditions have on the the likelihood of damage to the installed equipment

(C) SAP AG

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4.9 Structure Indicator

Edit mask



AN-ANN-N-X-X

Hierarchy levels

1 2 3 4 56

Location number

A1 A1-B A1-B02 A1-B02- 9 A1-B02- 9-C A1-B02- 9-C- 1

A = Alpha N = Numeric X = Alphanumeric

System Area Sub-area Function Sub-function Item

SAP AG 1999

The identification for functional locations is created using the structure indicator. The structure indicator consists of two input fields:  Edit mask  Hierarchy levels  The edit mask is used to control which characters may be used for identification (letters, numbers, or both) and how these characters are grouped together or split. The hierarchy levels are used to define which level ends at which character and how many hierarchy levels the structure may contain.  A functional location can be identified using a maximum of 40 characters (= maximum length of the edit mask). 

(C) SAP AG

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4.10 Master Record for Functional Location Functional location master record

Location A

Equipment usage

Location B

Classification

General

Documents / technical drawings

Location

Multilingual texts

Organization

Address / partner

Structure

Measuring points / 0 4 7 1 counters 0123 Permits



SAP AG 1999

The master record for the functional location uses the following views:  General: Class, object type, reference data, and manufacturer data.  Location: Location data, address  Organization: Account assignment (for example, company code, cost center), responsibilities (for example, maintenance planning plant)  Structure: For example, structure indicator, higher-level functional location, equipment  Additional data or links in the master record for the functional location can also be activated as tab pages or called up using pushbuttons (see graphic). 

(C) SAP AG

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4.11 Automatic Assignment Upon Creation

Existing functional locations

C1 Clarification plant C1-M Mechanical cleaning C1-M01 Sand trap

New functional locations



C1-B Biological cleaning C1-M02 Oil/fat trap

C1-M01-2 C1-M01-2 Ventilator Ventilator

C1-B01 Pump plant

C1-M02-2 Ventilator

C1-B01-1 Pump 1

C1-B02 Filtering station

C1-B02-2 Filter cell

SAP AG 1999

The structure of the functional location is based on the structure indicator. If you create a new functional location (for example, C1-M01-2), the system checks whether a hierarchy with this structure indicator already exists and whether the new identification is suitable for the existing hierarchy.  If this is the case, when the new functional location is created, it is included in the existing structure.  

(C) SAP AG

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4.12 Example of Functional Location Structure C1 Clarification plant

C1-M Mechanical cleaning C1-M01 Sand trap

C1-M02 Oil/fat trap

C1-B Biological cleaning C1-B01 Pump plant

C1-B02 Filtering 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 Valve 1 

Valve 2

C1-B02-2C/1 C1-B02-2C/2 Valve 1

Valve 2

SAP AG 1999

(C) SAP AG

LO100

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4.13 Technical Objects: Equipment

 Functional locations  Equipment  Bills of material



SAP AG 1999

(C) SAP AG

LO100

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4.14 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



SAP AG 1999

A piece of equipment is an individual physical object that is to be maintained as an autonomous unit. Pieces of equipment usually represent single objects (for example, pumps, motors, vehicles), for which maintenance tasks should be recorded.  Equipment can be installed at functional locations.  

(C) SAP AG

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4.15 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

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 tasks are required for an object and must be recorded  Technical data for this object must be collected and evaluated over long periods of time  The costs of maintenance tasks for this object are to be monitored  You need to record the usage time of this object at functional locations

(C) SAP AG

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4.16 Equipment Master Record Location A

Equipment Equipment master master record record

Equipment usage

Location B

Classification

General General

Documents / technical drawings

Location Location Multilingual texts

Organization Organization

Address / partner

Structure Structure

Measuring points / counters

0471 0123

Permits Internal note 

SAP AG 1999

The equipment master record uses the following views in the standard system:  General: Class, object type, reference data, and manufacturer data.  Location: Location data, address  Organization: Account assignment (for example, company code, cost center), responsibilities (for example, maintenance planning plant)  Structure: For example, structure indicator, higher-level functional location, equipment  Additional data or links in the master record for the equipment can also be activated as tab pages or called up using pushbuttons (see graphic).  You can use the time-based data to monitor a piece of equipment dynamically, that is, track changes to the equipment over a specific period of time. If your system is customized accordingly, it automatically creates a new time segment whenever certain changes are made in the master record. The time segment describes the equipment usage. 

(C) SAP AG

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4.17 Installation/Dismantling of Equipment



 

SAP AG 1999

Equipment can be installed and dismantled at functional locations. You can monitor the installation times for a piece of equipment from both the functional location view and the equipment view.

(C) SAP AG

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4.18 Prerequisites for Equipment Installation

Functional location

Equipment

Equipment category Equipment installation allowed?





Individual installation?

Equipment installation allowed?

SAP AG 1999

Two prerequisites must be fulfilled for a piece of equipment to be installed at a functional location:  The equipment category must permit an installation (Customizing).  The option "Equipment installation allowed" must be activated in the master record for the functional location. You can restrict this option by using the "Individual installation" option.

(C) SAP AG

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4.19 Equipment Usage List S-15

Usage list

03/01/ - 09/20/98



  

S-15

SAP AG 1999

The installation locations for equipment are documented within a technical system. The usage list forms part of the equipment history. Equipment usage periods can also be displayed from the functional location view.

(C) SAP AG

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4.20 Technical Objects: Bills of Material

 Functional locations  Equipment  Bills of material



SAP AG 1999

(C) SAP AG

LO100

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4.21 Bills of Material in a Company

Production bill of material

Engineering/design bill of material

Maintenance bill of material 

Costing bill of material

SAP AG 1999



Bills of material are used for different purposes. The usage depends on the enterprise area, for example:  The engineering/design bill of material includes all the elements of the product (from an engineering viewpoint) and contains the technical data. It is usually not dependent on the order.  The production bill of material includes the items (from a production viewpoint) and assembly conditions. For the assembly, for example, only items relevant to production with process-oriented data are required.  The costing bill of material reproduces the product structure and forms the basis for automatic determination of the material usage costs for a product. Items that are not relevant for costing are not included in this bill of material.



Instead of a uniform bill of material, these areas use "their own" bill of material with area-specific data (for example, production). They only evaluate bills of material containing area-specific data. This results in a targeted bill of material explosion, whereby only the area-specific data is made available. Data selection is controlled using the definition of the bill of material usage. A determination sequence by bill of material usage is defined in Customizing for selecting the correct bill of material for an application.

(C) SAP AG

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4.22 Bills of Material in Plant Maintenance

Structuring of object

Spare parts planning in order

Technical object

Maintenance bill of material Spare parts planning in task list 

SAP AG 1999

The maintenance bill of material differs from other BOMs in that it only contains items relevant to Plant Maintenance.  The maintenance bill of material has three important functions:  Structuring of the object The structure of an object should be displayed as clearly as possible from a maintenance viewpoint.  Spare parts planning in the order If a bill of material exists for a technical object, it can be used during the planning process of a maintenance order for the purpose of spare parts identification and planning.  Spare parts planning in the task list Spare parts can be planned in the task list based on a bill of material. 



Three are three categories of maintenance bill of material:  Material BOM  Equipment BOM  Functional location BOM

(C) SAP AG

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4.23 Bills of Material: Example of Material BOM Material M-1521

Object master record, Structure view Material BOM



10 Casing type A

100-100 1

PC

20 Compressor

100-200 1

PC

30 Seal

100-300 4

PC

40 Spool

100-400 1

PC

50 Screw

100-500 9

PC

60 Spacer

100-600 5

PC

70 Shaft type A

100-700 1

PC

80 Locking pin

100-800 2

PC

90 Valve

100-900 1

PC

Construction type field

Material BOM as maintenance bill of material

SAP AG 1999

Material BOMs are always used in Plant Maintenance if a number of similarly constructed objects have to be maintained. The aim is not to create a bill of material for each technical object, but to create just one bill of material and then assign this to the technical objects. This avoids the use of redundant bills of material.  A material BOM is a bill of material that is first created for a material independently of a technical object. To do this, you must:  Create a material  Create a material BOM for the material  The bill of material can then be assigned to one or more technical objects (equipment or functional location). You can make the assignment(s) in the respective technical object master record using the Structure view. The number of the corresponding material is entered in the Construction type field. 

(C) SAP AG

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4.24 Technical Objects: Unit Summary

You are now able to:  Describe the concept and criteria for functional locations  Describe the concept and criteria for equipment  Create a piece of equipment  Describe the application of bills of material in Plant Maintenance



SAP AG 1999

(C) SAP AG

LO100

24

4.25Exercises Unit: Technical objects Topic: Functional locations

At the conclusion of these exercises, you will be able to:  Display the structure of functional locations  Explain how a structure indicator is configured

In order to represent the systems and buildings, you must first consider how to configure the structure and the degree of detail required. At IDES, the workshops and technical systems should be represented using a hierarchy of functional locations which is defined using a structure indicator.

1-1

Displaying the Structure of a Functional Location Display the structure for clarification plant ##. Which functional locations are used for the valves in the pump station for biological cleaning? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

1-2

Display the functional location ##-B02. What is the name of the maintenance plant? To which cost center is the functional location assigned? Who is the person responsible for the cost center? What is the main work center called?

(C) SAP AG

LO100

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1-3

Display the structure of functional location ##-B02 graphically. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

1-4

Which structure indicator is used by clarification plant ##? What are the effects of the structure indicator? What is the edit screen and what does it mean? What is the maximum number of levels which the hierarchy can have? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

(C) SAP AG

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26

Unit: Technical objects Topic: Equipment

At the conclusion of these exercises, you will be able to:  Create an equipment master record  Install a piece of equipment

At IDES, individual physical aggregates, such as pumps and motors, which have to be exchanged frequently and whose lifecycle should be monitored exactly, are represented as pieces of equipment.

2-1

Display the equipment master Display the equipment with equipment number TEQ-## and determine the following data:

Description Acquisition date Acquisition value Manufacturer Category Maintenance plant Cost center Construction type Maintenance planning plant Main work center (C) SAP AG

LO100

27

2-2

Create an equipment master Create a new piece of equipment TEZ-##. You can freely select the data in the area 'General'. The maintenance plant is 1000, cost center 4110. How do you proceed? What is the system status after you have created the piece of equipment? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

2-3

Install equipment Install the new piece of equipment in the pump station for biological cleaning in your clarification plant ##. How do you proceed? Check the installation using the structural display for functional locations. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

2.4

Usage List

2-4-1 Display the pump P-1000-N001. When and at which functional location was the equipment installed for the first time? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 2-4-2 Which pieces of equipment were installed in the filter station for clarification plant C1 in the time between 01/01/1998 and 01/01/1999? Use the structural display for this. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

(C) SAP AG

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Unit: Technical objects Topic: Bills of material

At the conclusion of these exercises, you will be able to:  Explain the purpose of bills of material in Plant Maintenance  Display the bill of material for a piece of equipment  Assign a material BOM to a piece of equipment At IDES, all the individual parts for functional locations and pieces of equipment, for which no history is required but where spare parts planning is important, should be represented using bills of material.

3

The structure of your equipment TEZ-## should be represented for Plant Maintenance using a material BOM. Since TEZ-## and TEQ-## are constructed in the same way, you can use the same material BOM P-1000.

3-1

Assign the material BOM P-1000 to your piece of equipment. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

3-2

What is the material number of the pressure cover for the pump and how can this be determined from the master record for the equipment? ____________________________________________________________ ____________________________________________________________

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4.26Technical Objects: Solutions Unit: Technical objects Topic: Functional Locations

1-1

SAP menu  Logistics  Plant Maintenance  Technical Objects  Functional Location Structural Display Field name or data type

Values

Functional location

##

Number levels below

1

Location hierarchy



Explode pump station for biological cleaning step-by-step: Field name or data type

Values

Valves

##-B02-2A/1 ##-B02-2C/1 ##-B02-2A/2 ##-B02-2C/2

1-2

Double click on ##-B02 from the structural display or choose: SAP menu  Logistics  Plant Maintenance  Technical Objects  Functional Location Display

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Field name or data type

Values

Maintenance plant

1000 (“Location” tab page)

Cost center

4110 (“Organization” tab page)

Cost center manager

Linden (double click on cost center)

Main work center

MECHANICS (“Organization” tab page)

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1-3

SAP menu  Logistics  Plant Maintenance  Technical Objects  Functional Location  Structural Display Set 'As graphic' indicator and execute

1-4

SAP menu  Logistics  Plant Maintenance  Technical Objects  Functional Location  Display 'Structure' tab page, 'StrIndicator' field The structure indicator sets the default structure and labeling options for a functional location. This enables you to draw conclusions about the position of the functional location in the hierarchy from its label. In the same way, newly-created functional locations are automatically arranged in the correct position in an existing hierarchy. Then: Go back using the green arrow (or using the F3 function key); on the initial screen for displaying the functional location, you will now see the edit screen and number of hierarchy levels: Edit screen: XX-XXX-XX/X If a character is represented by X, you can use either a numerical or an alphanumerical character. Other options for representing characters are A (= alphanumerical) or N (= numerical). The edit screen also specifies which separators are allowed. Maximum number of hierarchy levels: 6

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Unit: Technical objects Topic: Equipment

2-1

2-2

Field name or data type

Values

Description

Electric pump ##

Acquisition date

01.07.1994

Acquisition value

2.513, 55

Manufacturer

Vereinte Mechanische Werke AG

Category

P-I

Maintenance plant

1000

Cost center

4110

Construction type

P-1000

Maintenance planning plant

1000

Main work center

T-ME##

SAP menu  Logistics  Plant Maintenance  Technical Objects  Equipment  Create (General) 'General' tab page: User-defined data 'Location' tab page: Maintenance plant 1000 'Organization' tab page: Cost center 4110 System status after creation: AVLB (= available)

2-3

SAP menu  Logistics  Plant Maintenance  Technical Objects  Equipment  Change Change structure of installation location > In the 'FunctLocation' field, enter label ##-B01 and confirm or SAP menu  Plant Maintenance  Technical Objects  Functional Location  Structural Display Enter label ##; confirm; open structure for biological cleaning; double-click on location ##-B01; Functional Location Display Change; 'Structure' tab page; in the

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area 'Equipment', symbol for 'Sub-equipment'; enter TEZ-## in the list and save. System status after installation: INST (= equipment installed) Subsequently: SAP menu  Logistics  Plant Maintenance  Technical Objects  Functional Location Structural Display Enter location ##-B01 and activate the indicator "Equipment installed"

2-4

Usage List

2-4-1 SAP menu  Logistics  Plant Maintenance  Technical Objects  Equipment  Display Extras  Usage list Field name or data type

Values

Installation date

06.12.1994

FunctLoc.

C1-B01-1

2-4-2 SAP menu  Logistics  Plant Maintenance  Technical Objects  Functional Location Structural Display Detailed view by double-clicking or magnifying glass on C1-B02: then Structure  Equipment Enter time period; equipment installed: P-1000-N001, M-1000-N051

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Unit: Technical objects Topic: Bills of material

3-1

SAP menu  Logistics  Plant Maintenance  Technical Objects  Equipment Change 'Structure' tab page, field 'ConstType': Construction type field Enter material P-1000 Save equipment

3-2 SAP menu  Logistics  Plant Maintenance  Technical Objects  Equipment Change “Structure list” button or Structure  Structure list Material number for pressure cover: 100-400

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5 Breakdown Maintenance

Contents:  Entering a breakdown order  Completion confirmation and completion of a breakdown order

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5.2 Breakdown Maintenance: Unit Objectives

At the conclusion of this unit, you will be able to:  Enter an order and put it in process  Enter a time confirmation for the order  Complete an order

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5.3 Course Overview Diagram



Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook

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5.4 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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5.5 Breakdown Maintenance: Entering an Order

 Entering a breakdown order  Completion confirmation and completion of a breakdown order

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5.6 Cycle of Maintenance Processing

1

Notification

2

Planning

3

Scheduling

4

Execution

5

Completion

• Technical object • Description

• Date • Malfunction

• Work to be performed • Material • Internal/external resources • Tools

• Order release • Printout

• Capacity leveling • Availability check

• Planned/unplanned material withdrawal • External procurement

• Time confirmation • Order settlement • Technical completion • Technical confirmation

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

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5.7 Cycle of Breakdown Maintenance Phase

Contents

Notification

1

Planning Scheduling

2

Execution

3

Completion

Roles

•Technical object •Description

•Date •Malfunction

•Work to be performed •Material •Internal/external resources •Tools

•Order release •Printout

Maintenance planner

•Capacity leveling •Availability check

•Planned/unplanned material withdrawal •External procurement •Time confirmation •Order settlement •Technical •Technical completion confirmation

Technician

Maintenance supervisor

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

SAP AG 2001

The five-step cycle of corrective maintenance processing is reduced to a three-step cycle for breakdown maintenance:  The starting point (step 1) is the creation of a maintenance order (possibly using data from the maintenance notification) for damage or a malfunction. This maintenance order is not planned, but is immediately released for processing. Any order papers required are also printed.  The execution phase (step 2) involves the withdrawal of spare parts from the warehouse and the actual execution of the order.  After the work has been completed, the actual time required is confirmed (step 3). Technical confirmations are also entered to record the repair and condition of the technical system. The order is settled in Controlling. 

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5.8 Business Process for Breakdown Maintenance Production

Maintenance planner

Order

Order: create and release

Call / message

0010 Check pump 0020 Renew seals

Technician

Maintenance supervisor Malfunction: correct/ confirm



Order complete

SAP AG 2001

Breakdown maintenance involves the creation and release of the maintenance order in one work step after a malfunction has been reported (for example, by an employee in Production).  Depending on the organization, this step is performed by the maintenance supervisor or the central maintenance planner.  The malfunction is corrected by a maintenance work center named in the order.  After the malfunction has been corrected, the order is confirmed by the person performing the task, the maintenance supervisor and the maintenance planner, and then completed by either the supervisor or the maintenance planner. 

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5.9 Order: With or Without Notification Order

A Order Create and release

0010 Pump leaking

Order

Notification Malfunction start: 06.05.2000, 6:31

B 

0010 Pump leaking

Damage: Leakage

SAP AG 2001

The breakdown order can be created directly without any previous requisition note (A). The order usually refers to a technical object (functional location or equipment) and is configured at a work center. In the first operation, the malfunction to be corrected is broadly described.  However, the breakdown order can also be created in combination with a maintenance notification (B), if malfunction data should be stored at this time for later documentation (for example, malfunction start or damage). The order thereby contains the same data as in case A and the notification contains all the data relevant for the documentation or history.  Both the order and notification data is entered on the same screen.  The notification can be supplemented and completed later. 

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5.10 Maintenance Processing Instruments

Order Notification Damage: Leakage Cause: Overload Activities: Pump checked Seals renewed

0010 Check pump 0020 Renew seals

Order

Notification

 Planning  Cost collection



 Requisition note Combined usage of order and notification in maintenance processing

 Documentation

SAP AG 2001

Two instruments are available for processing maintenance tasks: Orders are used to plan maintenance tasks and plan or track the costs incurred. The planning functions do not necessarily have to be executed here - orders can also be created as immediate orders without any planning.  Notifications are used to convey maintenance requirements and the documentation for technical findings and activities performed.  Orders and notifications can be used independently of one another. However, they are usually combined to utilize the advantages of both instruments.  Special case: Entering an order and notification in one work step During the processing of breakdown maintenance, the malfunction order can be created together with a malfunction report. The notification areas - malfunction data, damage and notification dates are thereby shown on the order header. This has the advantage that important malfunction data can also be entered for the subsequent documentation when the order is created.  

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5.11 Maintenance Order: Putting in Process

Status 'RELEASED' Order

Putting in process

0010 Check pump

Shop papers 0020 Renew seals

Save 

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The function 'Put in Process' releases the order, prints the required order papers, and finally saves the order.  You can execute the following activities after releasing the order: 

Withdraw material Post goods receipts Enter time confirmations

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5.12 Breakdown Maintenance: Task Completion

 Entering a breakdown order  Completion confirmation and completion of a breakdown order

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5.13 Time Confirmations Initial screen

Individual entry Collective entry Collective entry using operation list Overall completion confirmation

Scope

Partial confirmation Final confirmation

Cancellation option



    



SAP AG 1999

In most cases, breakdown maintenance involves one order with only one operation. For this reason, you can use the individual entry function for time confirmation. Here you can enter the actual time directly on the detail screen for the operation confirmation. When confirmations of operations have been entered for a maintenance order, these operations are automatically assigned the status "Partially confirmed" by the system. As soon as all the operations for a maintenance order have been completely confirmed, the order itself is assigned the status "Finally confirmed". There is always a risk of completion confirmations being assigned to the wrong operations or entered with the wrong data. The system therefore allows you to cancel completion confirmations, if required. Instead of using individual entry, you can use the overall completion confirmation function to enter not only the times, but also, for example, material withdrawals, and counter readings on a single screen.

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5.14 Maintenance Order: Technical Completion

Order 901760 Limited ability to change order Status 'Technically completed' Determine location and account assignment data Create settlement rule Set deletion flag for purchase requisitions Close open reservations Close open capacities













SAP AG 1999

When activities for order execution and completion are finished, the maintenance order obtains the status 'Technically completed'. In other words, the maintenance work required for this order has been completed. The maintenance order can then only be changed online as follows:  It can be locked or unlocked.  The deletion flag can be set. The location and account assignment data specified for the maintenance order is fixed and can no longer be changed. However, the order can still receive costs, for example, invoice receipts for materials delivered and consumed. If you have not maintained a settlement rule for the maintenance order, it is created automatically by the system. If this is not possible, the system directs you to where the settlement rule can be maintained manually (see also settlement rule). It is possible to reset the status “Technically completed” of an order, if required.

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5.15 Breakdown Maintenance: Unit Summary

You are now able to:  Create a breakdown order  Confirm and complete a breakdown order

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5.16Processing

Malfunction-based Plant Maintenance:

Exercises Unit: Breakdown maintenance Topic: Order entry

At the conclusion of these exercises, you will be able to:  Create a breakdown maintenance order and put it in process

When a machine or technical system breaks down, a breakdown order should be created, in which only the most important data is recorded, to ensure a quick response.

1

Creating a Maintenance Order Without a Maintenance Notification Set up a maintenance order for your equipment TEQ-## as a breakdown maintenance task and enter the priority “Very high”.

1-1

Which order type do you choose? ____________________________________________________________

1-2

Which start and end dates are displayed based on the priority? Start date: End date:

1-3

Which other data is proposed? Where does this data come from? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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1-4

Which system status does the order have at this point? ____________________________________________________________

1-5

Put the order in process without printing it. Which order number is assigned? How has the system status changed? ____________________________________________________________ ____________________________________________________________

2

Create a maintenance order including maintenance notification For a breakdown maintenance task, you set up a maintenance order combined with a notification, since you want to keep malfunction data determined now to document it later. Configure the maintenance order for your piece of equipment TEQ-## and assign priority “Very high”.

2-1

Which order type do you choose? ____________________________________________________________

2-2

Enter a malfunction start (date, time) and select the switch field for a breakdown. Enter a suitable damage code. How do you proceed? Put the order in process without printing it. Which order number was assigned? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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Unit: Breakdown Maintenance Topic: Order completion

At the conclusion of these exercises, you will be able to:  Confirm a breakdown order  Complete a breakdown order

After the malfunction has been corrected, the breakdown order is confirmed and completed. The completion confirmation usually contains the confirmation of work times performed (time confirmation). It can also contain a technical confirmation (for example, causes of damage, activities performed) which can be executed in a maintenance notification. 3

Confirming a Breakdown Order Enter an individual confirmation for both your maintenance orders created above. Which menu path do you use? ____________________________________________________________ ____________________________________________________________ Set the final confirmation indicator.

4

Technical Confirmation Complete the maintenance notification which you have created together with your second order. Enter a malfunction end a suitable cause of damage. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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5

Completing a Breakdown Order

5-1

Which status does the order have before the technical completion? ____________________________________________________________

5-2

Technically complete your maintenance orders. How do you proceed? ____________________________________________________________

5-3

Complete the notification as well. Which indicator do you set? ____________________________________________________________

5-4

Which status does the order have after the technical completion? ____________________________________________________________

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5.17Solutions Unit: Breakdown Maintenance Topic: Order Entry

1-1 Field name or data type

Values

Order type

PM01

Field name or data type

Values

Start date

Current date

End date

Current date + 1

1-2

1-3 Default Data: Field name or data type

Values

From the equipment master

Maintenance planner group Main work center Functional loc.

From Customizing

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1-4 System Status

1-5

Field name or data type

Values

CRTD

Created

MANC

Material availability not checked

NTUP

Dates are not updated

Press “Put in process” button (white paper with cogwheels) Order number: 8120xx Order  Change System status Field name or data type

Values

REL

Released

SETC

Settlement rule created

NMAT

No material components

PRC

Pre-costed

Field name or data type

Values

Order type

PM05

2-1

2-2

Enter a malfunction start using "Malfunction data" tab page (belongs to notification and is shown on the order header) and set the indicator for a breakdown; then enter a suitable damage using "Damage" tab page: To do this, position the cursor in the “Damage” field and use F4-Help, for example, to select a damage from the code group PUMP/100. Then press button “Put in process” (white paper with cogwheels).

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Unit: Breakdown Maintenance Topic: Order Completion

3

Confirming a Breakdown Order SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Entry  Individual Time Confirmation

4

Field name or data type

Values

Actual work

For example, 5 hours

Final confirmation



SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change Choose symbol for notification Enter the malfunction end in the area for malfunction data. Select the cause code in the area for the item: To do this, position the cursor in the “Cause code” field and use F4-Help, for example, to select a cause from the code group PM01.

5-1

In change mode for the order (path - see 4) System status Field name or data type

Values

REL

Released

CNF

Confirmed

SETC

Settlement rule created

NMAT

No material components

PRC

Pre-costed

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5-2

In change mode for the order (path - see 4)

Field name or data type

Values

Technically complete the order

Function 'Complete (technically)'

Field name or data type

Values

Completing the notification

Indicator 'Complete notifications'

5-3

5-4 System Status

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Field name or data type

Values

TECO

Technically completed

CNF

Confirmed

SETC

Settlement rule created

NMAT

No material components

PRC

Pre-costed

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6 Corrective Maintenance

Contents:  Notification of maintenance requirements  Planning of orders  Scheduling of maintenance tasks  Execution of maintenance tasks  Completion of notifications and orders

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6.2 Corrective Maintenance: Unit Objectives

At the conclusion of this unit, you will be able to:  Report maintenance requirements including information about the object, damage, or malfunction  Plan orders with operations, stock and non-stock material, utilities, and costs  Release and print orders  Make planned and unplanned withdrawals of material from the warehouse  Confirm orders with actual times  Enter technical completion confirmations  Complete and settle maintenance tasks

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6.3 Course Overview Diagram



Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook

SAP AG 2001

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6.4 Corrective Maintenance: Business Scenario

 At IDES, the maintenance requirements are collected and then dealt with during order processing.  This processing involves the steps notification, planning, scheduling, execution, and completion.

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6.5 Corrective Maintenance: Notification of Maintenance Requirements

 Notification of maintenance requirements  Planning of orders  Scheduling of maintenance tasks  Execution of maintenance tasks  Completion of notifications and orders

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6.5.2 Cycle for Corrective Maintenance Phase

1

Contents

Notification

2

Planning

Technical object Description

Roles Due date Malfunction

Production worker Maintenance planner

Work Work to to be be performed performed Material Material Internal/external Internal/external resources resources

3

Scheduling

Order Capacity Order release release Capacity leveling leveling Printout Availability Printout Availability check check

4

Execution

Planned/unplanned Planned/unplanned material material withdrawal withdrawal External External procurement procurement

5

Completion

Time Time confirmation confirmation Technical Technical completion completion Technical Technical confirma confirma

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

    

SAP AG 2001

The starting point for corrective maintenance (step 1) is the notification of damage, a malfunction, or some other request (for example, a request for modification work). The notification usually refers to a technical object and contains a description of the malfunction or requirements. In addition, data can be entered in a notification to build up the history (for example, damage, causes and so on). A maintenance task, which is very frequently processed using a maintenance order, is introduced owing to the request or malfunction. A notification does not necessitate the creation of an order in every case.

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6.5.3 Maintenance Notification: Structure

Notification

Date / time / reported by Description Maint. object: Functional location Equipment Assembly Material serial number Location data Breakdown / availability Damage location Damage Cause of damage

Notification Text items

Activities

Tasks



Activity Execution factors

Dates Task description

SAP AG 1999

Each maintenance notification contains header data. Header data is information used to identify and manage the maintenance notification. This data is valid for the entire maintenance notification.  You enter and maintain data in the notification item sub-screen area to specify object parts, damage and cause in detail. A notification can identify several items for which similar data can be maintained.  Activities document the work performed for a notification. They are particularly important for inspections, because they can prove that certain tasks have been performed.  The task data describes activities that should still be performed, and which may have only arisen after the maintenance task was executed (for example, creating a report). 

However, in some cases, you can also use tasks for planning purposes (for example, if order processing is not active). In this case, you can plan to use different people to process the notification, and monitor the execution of activities for specific periods of time. Note, however, that no cost monitoring, material planning or capacity requirements planning is possible for this type of processing.  If the notification is used for a maintenance task without an accompanying order, no costs, material consumption or planning details for execution are maintained.

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6.5.4 Objects in Maintenance Notification

Material with serial number Assembly

Equipment Functional location

Or no object 

SAP AG 2001

All the types of maintenance notification mentioned can be entered for both a functional location and a piece of equipment, in each case with or without assembly, or for a material with serial number. The hierarchy for these objects corresponds to the sequence specified. In other words, if you enter a maintenance notification for an assembly on a piece of equipment, which is assigned to a functional location, the system transfers all the relevant data for the piece of equipment and the functional location.  However, you can also enter these maintenance notifications without specifying an object number. This is the case, for example, if a malfunction report refers to an object that is not managed in the system under a number, or if a maintenance request refers to a new object to be provided for an investment program.  The view for the reference object can be selected for an individual notification or notification type as follows: o Functional location + Equipment + Assembly (standard setting) o Functional location + Equipment + Assembly, for functional locations with exactly one piece of equipment installed, the equipment is set automatically. o Functional location o Equipment (with or without assembly) o Material number + Serial number (with or without equipment number) o Without reference object 

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6.5.5 Maintenance Notification: Object Information

Orders Maintenance dates

Documents

i

Notifications

Processing days

Object information

Links

Structure list Breakdowns



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You can use the object information to obtain a swift overview of the condition and history of the object concerned.  The dialog box contains data (where available) about the classification of the object. It displays statistics for the maintenance notifications related to the object and the last three maintenance notifications entered for this object with short text, date, and completion. You can also call up information about orders, maintenance items, and maintenance dates.  The dialog box can be displayed automatically if required, provided that certain conditions are fulfilled. For example, you can make settings in Customizing so that object information is only displayed if a certain number of notifications for this object are still outstanding at a specified time or if the object has certain characteristics. In this way, you (as the person who entered the notification) automatically receive any important information at this point. 

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6.5.6 Catalogs

Catalogs for Object part

Cause of damage

Damage

Activity

Catalog structure:

Example: Damage catalog

Catalog

Mechanical damage

Code group

Code 010 020 030 .. .

Code



Task

Corrosion Broken glass Engine defect .. .

SAP AG 1999

Catalog: Combination of code groups, grouped together according to content (for example, damage and cause of damage).  Code groups: Combination of code groups, grouped together according to content (for example, damage to vehicles, pumps, motors) or mechanical damage and electrical damage.  Codes: Description of damage and activity.  Advantages of catalogs:  Reduction in number of incorrect entries  Codes can be used as the starting point for workflow and follow-up actions  Statistical evaluations are possible using the standard analyses in the Plant Maintenance Information System 

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6.5.7 Catalogs and Catalog Profiles Catalog C: Damage Group 1000: General damage 1000 Corroded 1100 Broken 1200 Dirty 1300 Leaking 1400 ....... 1500 .......

........ ........

Catalog profile P01: Centrifugal pumps

C Damage 001 1000 002 5400 2 Tasks ..... 5 Causes 8 Activities B Object parts

..... ..... .....

Group 5400: Pumps 1000 Unbalanced rotor blade 1100 Crack on motor casing 1200 Cable burnt out 1300 Porous seal ring 1400 ..... 1500 ....





Equipment / functional location

Notification type

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In the catalog profile, you can define which code groups can be used when processing a specific object. The advantage here is that only the code groups relevant for the object are displayed.

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6.5.8 Selecting Maintenance Notifications Why ? Find particular maintenance notification Process several maintenance notifications simultaneously Restrict planning worklist Scope Notification Notification items Tasks Customizing Selection conditions Field selection Functions Different sorting Select / delete complete list Different list fields, internal display variant Display breakdowns graphically Excel spreadsheet processing 



SAP AG 1999

There are many reasons why the list editing features of the system can support you when selecting maintenance notifications, tasks, and items. For example, if you want to:  Change or display a specific maintenance notification, but do not know its number.  Change or display several maintenance notifications which have certain features.  Execute a specific function simultaneously for several maintenance notifications which have certain features (for example, printing, creating an order).  Obtain an overview of all the notification tasks that meet specific criteria.  Have a list of all the notification items that meet specific criteria.

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6.5.9 Selection Hit List: ABAP List Viewer

 Sorting according to several columns  Drag & Drop  User-specific variants



Created

Selected

Notification



10000497

Breakdown

Martin



10000498

Malfunction

Martin

10000499

Cleaning required

Martin

10000500

Check pump

Martin

Description

SAP AG 1999

The ABAP List Viewer with GRID control technology is available to display the objects identified using the list selection. GRID control is a flexible, new tool for displaying lists using a new graphical user interface. In this list, you can use the following functions: - Move using Drag&Drop - Make columns wider or narrower - Select - Sort  The list can be sorted according to several fields at once (for example, if an order list should be sorted first by cost center and then by date within the cost center).  You can also change lists using a customer exit (for example, to add headings or change print parameters). 

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6.5.10Notification

of Maintenance Requirements:

Exercises Unit: Corrective Maintenance Topic: Notification of Maintenance Requirements At the conclusion of these exercises, you will be able to:  Describe the structure of a maintenance notification  Create notifications of different notification types  Select and further process maintenance notifications As a preliminary stage in order planning, notifications are collected in the form of requests or malfunction reports and converted into orders by the maintenance planner or combined in an order, for example, according to object.

1-1-1 Creating a Maintenance Request Create a maintenance request for equipment P-1000-N001; a new welded joint is to be made on the casing of the pump motor. Which notification number is assigned?

Enter a description of the damage and a long text. Which log entry is in the long text?

Assign the maintenance request to your maintenance planner group I## and your work center T-ME##. 1-1-2 Assign an assembly Select an appropriate maintenance assembly. How do you proceed? Which data have you entered? (C) SAP AG

LO100

14

1-1-3 Object information Obtain information about the equipment from the object information screen. From which date onwards does the system search for the information?

How many completed orders are there?

What is the diameter of the running wheel?

Which documents are assigned?

How can maintenance dates, which may be set for the reference object, be checked?

Save the maintenance request.

1-2-1 Creating a Malfunction Report Create a malfunction report for your pump TEQ-##: the electric supply cables are broken and must be renewed. Enter a malfunction start in the malfunction report and set the breakdown indicator. Which notification number is assigned?

1-2-2 Damage code and cause code Specify an appropriate damage in your malfunction report and, if already known, a cause of damage. Which data have you entered? (C) SAP AG

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Damage/code group: Cause/code group:

1-3-1 Selecting Maintenance Notifications Select all the maintenance notifications created in this course (in display mode). Which selection criteria do you choose?

1-3-2 Display the list so that you can see who created the maintenance notifications and when; then sort the list alphabetically by the name of the person who entered the notification. How do you proceed?

1-3-3 You want to save the relevant settings in the list for future list displays. How do you save the current settings as a display variant? How can this variant be set as the standard variant?

(C) SAP AG

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6.5.11Notification of Maintenance Requirements: Solutions Unit: Corrective Maintenance Topic: Notification of Maintenance Requirements

1-1-1

Creating a Maintenance Request

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Notification  Create (Special)  Maintenance Request Field name or data type

Values

Short text

Provide new weld joint

Long text (button Create text)

Enter text as required

Log book entry

Name, date, time This means that under certain circumstances several employees can process a notification.

Reference object (equipment)

1-1-2

P-1000-N001

Assign an assembly

Symbol 'Structure list'

1-1-3

Object information

Field name or data type

Values

Selection date

05/1997

Completed orders

3

Running wheel diameter

130 mm

Documents

DOC H-1000

001 00

DRW P-1000 001 00 Next maintenance date

1-2-1

(C) SAP AG

15th of the following month

Creating a Malfunction Report

LO100

17

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Notification  Create (Special)  Malfunction Report Notification number: 1-2-2

10000xxx

Damage code and cause code

Field name or data type

Values

Damage/code group

For example, PUMP/100 1001

Cause of damage/code group

For example, PM02 1000

1-3-1

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Notification  List Editing  Display Selection criteria: For example, notification date from 'start date of course' until 'finish date of course' and reported by 'LO100*'

1-3-2

Display and sort list:

Settings  Display variant  Current: Select 'Created at' and 'Created by' Button '' and 'Copy' Select column 'Created by' and symbol 'Sort ascending' 1-3-3

Settings  Display variant  Save as variant

Enter variant name and variant description, then save >> A user-specific variant is created Settings  Display variant  Management...: Click on Initial variant field >> A green tick appears, save

(C) SAP AG

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6.6 Corrective Maintenance: Planning of Orders

 Notification of maintenance requirements  Planning of orders  Scheduling of maintenance tasks  Execution of maintenance tasks  Completion of notifications and orders



SAP AG 1999

(C) SAP AG

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6.6.2 Cycle for Corrective Maintenance Phase

1 2

Contents

Roles

Notification

Technical Due Technical object object Due date date Description DescriptionMalfunction Malfunction

Production Production worker worker Maintenance Maintenance planner planner

Planning

Work to be performed Material Internal/external resources

Maintenance planner

3

Scheduling

Order Capacity Order release release Capacity leveling leveling Printout Availability Printout Availability check check

4

Execution

Planned/unplanned Planned/unplanned material material withdrawal withdrawal External External procurement procurement

5

Completion

Time Time confirmation confirmation Technical Technical completion completion Technical Technical confirmation confirmation

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



SAP AG 2001

In step 2, the order is created and planned from the notification. Typical planning tasks include creating operations, reserving spare parts, or planning usage times.

(C) SAP AG

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6.6.3 Planning Alternatives: Internal or External Processing?

Internal processing





External processing

SAP AG 1999

In corrective maintenance, there are basically two options for assigning work to be performed:  For internal processing, internal workshops, which are defined in the system as maintenance work centers, execute the work.  For external processing, external companies are hired. There are three ways of representing this external service.

(C) SAP AG

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6.6.4 Creation of Maintenance Orders

Direct creation of order

Maintenance order / notification

Creation of order based on notification

Maintenance notification

Combination of maintenance notifications for maintenance order

Maintenance order

Maintenance notification Maintenance notification

Maintenance order

Maintenance notification

Entry of order with subsequent activity report

Maintenance order

Maintenance notification

Automatic generation of maintenance order from maintenance item

Maintenance item

Maintenance order



SAP AG 1999

1st scenario: The maintenance order is created directly = breakdown order 2nd scenario: The maintenance notification is entered locally. The maintenance order is created for the maintenance notification by the person responsible (unit 6: Corrective Maintenance)  3rd scenario: In a maintenance order, several maintenance notifications are combined into one or more objects (unit 6: Corrective Maintenance)  4th scenario: An activity report for an existing maintenance order is entered subsequently as a technical confirmation  5th scenario: A maintenance order is automatically generated from a maintenance item by the maintenance plan (unit 8: Preventive Maintenance)  

(C) SAP AG

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6.6.5 Elements of Maintenance Order

Order header

For example: Order type, dates, plant, main object, priority, description

Object list

Equipment (assembly), functional locations, maintenance notifications

Operation

For example: Work center, control key, description standard time, activity type, salary details Material list

For example: Material, quantity, storage location

Production resources/tools

Settlement rule

Costs (estimated / planned / actual) 





   



SAP AG 1999

Header data is information that serves to identify and manage the maintenance order. It is valid for the whole maintenance order - for example, the number, description and type of order, scheduled dates for order execution, priority of tasks, creator, and the last person who changed the order. Object list: The object list consists of functional locations and/or pieces of equipment and/or assemblies. You can enter these objects in the order header as reference objects and/or in the object list. You can use operations to describe the work to be performed when the maintenance order is executed. (For example, work center, standard time, control key) Materials are spare parts, which are required and used or consumed when the maintenance order is executed. Production resources/tools (for example, tools, protective clothing, and trucks) are required to execute the maintenance order, but are not used or consumed. The data in the settlement rule provides information on who usually bears the costs. It is proposed from the master record for the reference object and can be changed when the first settlement rule is maintained for the order. Cost data provides information on how high the estimated, planned and actual costs are in the value categories, which cost elements are relevant for the order, which key figures in the PMIS (maintenance information system) are updated based on the value categories, and how these key figures are updated by the actual costs for the order.

(C) SAP AG

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6.6.6 Operations

List of operations Operation



Work center

Control key

Description

0010

ME

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 2001

When you prepare work using operations, you can plan at three different detail levels, depending on the type of maintenance order and the scope of the work planned:  Short orders, which only contain a single operation (fast entry): For these orders, you can enter the data for an operation in the lowest section of the header data screen, without having to change screens. This operation can be either an internal or external process.  Extensive orders without detailed planning: For these orders, you use the operation overview. Here, you can enter any number of operations in list form.  Short or extensive orders with detailed planning: For these orders, you use the operation overview and the operation detail screens. For detailed information about internal processing, use the Operation Internal Processing screen. For detailed information about external processing, use the Operation External Processing screen. 

(C) SAP AG

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6.6.7 Maintenance Order: Object list

Order 901760

Object list 901760

M-1000-N001 M-1000-N002 Equipment or Functional locations or Notifications



 



  

SAP AG 2001

The object list is an integral part of the maintenance order. You use it to assign technical objects and/or maintenance notifications to the maintenance order. Even if no reference object has been specified for the maintenance order on the header data screen, you can assign technical objects and/or maintenance notifications to the maintenance order in the object list. If notifications are assigned to the order using the object list, the first notification in the order header appears in the 'Notification' field. Notifications, which have been assigned using the object list, can also be deleted from the object list, thereby removing the assignment to the order. If the order is created based on the notification or the notification is assigned to the order directly using the notification button, this assignment can no longer be deleted. The object list does not "control" the order - no adjustment of work to be performed, update of history or cost distribution will take place. You can use customer exit IWO10027 to distribute the order costs proportionately to the objects in the object list. . Customer exits are dealt with in the level three course.

(C) SAP AG

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6.6.8 Stock Material - Process Flow

Component assignment Material reservation

Availability check

Order release

Printing Automatic availability check







    

Goods issue

SAP AG 1999

You can plan materials, which are required to execute the task, for each operation in the maintenance order. The materials can either be bill of material components for the reference object or freely assigned materials. You cannot assign materials to sub-operations. The materials that you plan for the maintenance order will be reserved in the warehouse, if they are kept in stock. You can set the reservation time in your system using the Customizing function. In Customizing, it is decided for each order type, whether the system should make the material reservation effective and generate the purchase requisition immediately or only when the order is released. However, you can change the relevant indicator in the order header when processing the order. Note that you cannot reverse this change. An availability check can be called up when components are assigned in the order. An automatic availability check is performed when the order is released. The order can also be released even if there is no availability. A material pick list and material withdrawal slips can be printed together with the order papers. Planned goods issues are entered with reference to the reservation (reservation number), unplanned goods issues with reference to the order number. The goods issues entered can be displayed in the "Goods Movements for Order" function.

(C) SAP AG

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6.6.9 Non-Stock Material - Process Flow

Component assignment Purchase requisition Purchase order Order release Goods receipt Company

Invoice



      

xyz

Invoice receipt

SAP AG 1999

When components are assigned in the order, additional purchase information can be entered. Depending on the order type, the purchase requisitions are generated either when the order is saved or released. In purchasing, purchase orders are generated from purchase requisitions. The purchase order items are assigned to the maintenance order. Goods receipts with reference to the order can be entered as soon as the order has been released. When goods receipts are entered, the maintenance order is debited with the purchase order value. When the invoice is received, any invoice differences are automatically credited to, or debited from the maintenance order. The goods receipts entered can be displayed in the "Goods Movements for Order" function.

(C) SAP AG

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6.6.10 Central Address Management

Functional location

Maintenance order

Maintenance notification

Equipment

NSTO component Delivery address



SAP AG 1999

The following objects are linked to the new address management: - Functional location - Equipment - Notification - Order - Component for non-stock material (order)  You also have the option of specifying the delivery address for non-stock material in the order and transferring it to purchasing. The delivery address can also be derived automatically using definable rules.  The addresses for the notification and order are synchronized. 

(C) SAP AG

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6.6.11 Cost Analysis in Maintenance Order

By value category

By cost element Plan Actual

Plan Actual

Internal service External Service Warehouse issue Other

403000 Spare parts 415000 External material 615000 Labor hours

Maintenance order



SAP AG 1999

Operation 10 Operation 20 Operation 30 ...

You can display the expected costs in two ways:  At cost element level (Controlling view)  At value category level (Maintenance view)  In Customizing, cost elements are assigned to value categories. 

(C) SAP AG

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6.6.12Planning

of Orders: Exercises

Unit: Corrective Maintenance Topic: Planning of Orders

At the conclusion of these exercises, you will be able to:  Describe the structure of a maintenance order  Create operations  Plan material  Structure an object list  Manage addresses  Display the cost overview The order is the most important component in planning maintenance tasks. Operations and spare parts are planned and costs collected in the order.

2

Creating Orders

2-1

Creating an Order from List Editing for Maintenance Notifications Create a maintenance order for your malfunction report. How do you make the selection? How do you proceed?

Which order type is proposed and why?

Enter business area 1000. Which data is transferred from the malfunction report?

(C) SAP AG

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Save the order. Which number is assigned to it?

(C) SAP AG

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2-2

Create an order from the maintenance notification Create a maintenance order for your maintenance request. How do you proceed?

Attribute order type PM03 to your order, assign it to your work center T-ME## and business area 1000. Which order number is assigned? Call up your order again using 'Display maintenance order' and check which data has been transferred to the order header. Order short text

 Yes  No

Order long text

 Yes  No  Yes  No

Priority

 Yes  No

Maintenance planner group

2-3

Required start date

 Yes  No

Required end date

 Yes  No

Create an order directly The electric supply cables for three pumps in the clarification plant C1 are to be replaced. Create an order for this work directly (that is, without reference to a maintenance notification). Use order type PM01. Make the necessary entries in the object list. How do you make entries in the object list? ____________________________________________________________ ____________________________________________________________ Which pieces of equipment have you selected? ____________________________________________________________ Save the order. Which number is assigned to it? ____________________________________________________________

(C) SAP AG

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2-4

Operations Enter operations for your maintenance orders. Use the existing standard text to do this. Order 1: Order 2: Order 3: Which standard texts have you used? ____________________________________________________________ ____________________________________________________________ What extra step must be performed for order 3 (from exercise 1-3) with regard to the objects? When should you perform this step? ____________________________________________________________ ____________________________________________________________

2-5

Material planning

2-5-1 Material in general Assign material from the general material list to an operation in your order. Order: Operation: Material number: Required quantity: 2-5-2 Material from the bill of material In addition, assign a material to another operation in your order using the bill of material. How should you proceed? ____________________________________________________________ ____________________________________________________________ Operation:

Which bill of material is proposed? Why? ____________________________________________________________ ____________________________________________________________ (C) SAP AG

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____________________________________________________________ Material number: Quantity according to BOM: Required quantity in order: 2-5-3 Non-stock material Assign a non-stock item to your order. Operation: Material number: Item category: Purchasing group:

001

Price: Vendor:

1000

G/L account:

415000

Material group Check the delivery address for your non-stock item. Which menu path do you use? ____________________________________________________________ Which specifications are made? Why? Name: Postal code/City: Street: If you have not found a delivery address, enter a new one.

2-6

Planned cost estimate

2-6-1 Cost overview Display the cost overview for your order. Which menu path do you use? (C) SAP AG

LO100

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____________________________________________________________ Which valuation categories contain planned costs? Value category

Planned costs

2-6-2 Planned/actual comparison Determine the cost elements used by planned costs in your order. Which menu path do you use? ____________________________________________________________ Cost element

(C) SAP AG

Planned costs

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6.6.13Planning of Orders: Solutions Unit: Corrective Maintenance Topic: Planning of Orders

2

Creating Orders

2-1

Creating an Order from List Editing for Maintenance Notifications Select notifications(s), and then Notification  Create order Field name or data type

Values

Order type

Order type PM01 is proposed owing to Customizing settings

Data from malfunction report

Short text (not long text) Basic dates Reference object Priority

Order number

2-2

9020xx

Create an order from the maintenance notification Functions  Order  Create Order number: 9020xx

Data copied to the order header:

(C) SAP AG

Field name or data type

Values

Order short text

Yes LO100

36

2-3

Order long text

No

Priority

Yes

Maintenance planner group

Yes

Required start date

Yes

Required end date

Yes

Create an order directly 'Objects' tab page  Button 'Equipment selection': Selection 'Equipment description *pump*' Equipment:

For example:

Field name or data type

Values

10003419

Normal suction pump SIHI 200-200

10003420

Normal suction pump SIHI 200-200

10003421

Normal suction pump SIHI 200-200

Order number: 9020xx

2-4

Operations Standard texts: For example: PM000001 Deactivate and security check, and so on. Order 3: You must set the execution factor for the operations according to the equipment entered in the object list. If possible, the factor should only be set if the operations have been fully planned (and therefore after material planning), so that times and materials can be projected accordingly.

(C) SAP AG

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> Select operations and set the factor using button "Ex. factor"

2-5

Material planning

2-5-1 Material in general Field name or data type

Values

Order

9020xx

Operation

0010

Material number

For example, 100-100

Required quantity

For example, 12 pieces

2-5-2 Material from the bill of material How should you proceed?

Symbol 'Structure list'

Operation:

For example: 0020

Bill of material: The system proposes the bill of material of material P-1000. Reason: The piece of equipment does not have an equipment BOM, but is assigned to construction type P-1000 (= material P-1000) which has a material BOM. Field name or data type

Values

Material number

For example, 100-400

Quantity according to BOM

1 piece

Required quantity in order

For example: 3 piece

2-5-3 Non-stock material

(C) SAP AG

Field name or data type

Values

Operation

9020xx

Material number



Item category

N LO100

38

Purchasing group

001

Price

For example, 25 per 1 unit

Vendor

1000

G/L account

415000

Material group

For example, 007

Delivery address of the non-stock item: Component  Delivery address

2-6

Field name or data type

Values

Name

Astralis GmbH

Postal code/City

DE 69190 Walldorf

Street

Am neuen Schulhaus 4

Planned cost estimate

2-6-1 Cost overview In the order header, 'Costs' tab page Value categories: Value category

Planned costs

Internal material

309,00

External material

50,00

Internal labor

713,06

2-6-2 Planned/actual comparison Extras  Cost reports  Planned/actual comparison or the button Planned/actual comparison in the cost overview

(C) SAP AG

Cost element

Planned costs

400000 Raw materials consumed

225,00

415000 External procurement

50,00 LO100

39

(C) SAP AG

615000 Direct activity allocation

713,06

890000 Consumption of semifinished products

84,00

LO100

40

6.7 Corrective Maintenance: Scheduling of Maintenance Tasks

 Notification of maintenance requirements  Planning of orders  Scheduling of maintenance tasks  Execution of maintenance tasks  Completion of notifications and orders



SAP AG 1999

(C) SAP AG

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6.7.2 Cycle for Corrective Maintenance Phase

1

Contents

Notification

2

Planning

3

Scheduling

4

Execution

5

Completion

Technical Technical object object Description Description

Roles Due Due date date Malfunction Malfunction

Production Production worker worker Maintenance Maintenance planner planner

Work Work to to be be performed performed Material Material Internal/external Internal/external resources resources

Maintenance Maintenance planner planner

Order release Printout

Maintenance supervisor

Capacity leveling Availability check

Planned/unplanned Planned/unplanned material material withdrawal withdrawal External External procurement procurement

Time Time confirmation confirmation Technical Technical completion completion Technical Technical confirmation confirmation

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



SAP AG 2001

In step 3, the order is transferred to scheduling. Here, availability is checked, required capacity is provided, and the required shop papers are printed.

(C) SAP AG

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6.7.3 Selecting Maintenance Orders Why ? Find particular order Process several orders simultaneously Limit planning worklist Customizing Selection conditions Field selection Functions Different sorting Select / delete complete list Different list fields, internal display variant Display frequency statistics graphically Excel spreadsheet processing 

SAP AG 1999

You use the selection function for maintenance orders if you want to:  Change or display a particular maintenance order, whose number you do not know  Change or display several maintenance orders which have certain features  Obtain an overview of specific maintenance orders which have certain features  Execute the same function for certain maintenance orders, for example, release, print, or complete them  If you have created a list, which includes all the maintenance orders or operations required, you can process it using the following functions: o Sort list differently o Search list for specific character strings o Select list and list entries o Change field selection in list o Scroll and set scroll column o Process list with spreadsheet o Display graphic for frequency statistics o Display scheduling overview o Execute order functions in list o Download order data in list 

(C) SAP AG

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6.7.4 Selection Hit List: ABAP List Viewer

 Sorting according to several columns  Drag&Drop  User-specific variants

Selected

Order

Created



810380

Breakdown

Martin



810381

Malfunction:

Martin

810382 810383



Description

Cleaning required Check pump

Martin Martin

SAP AG 2001

The ABAP List Viewer with GRID control technology is available to display the hit list selection. GRID control is a flexible, new tool for displaying lists using a new graphical user interface. In this list, you can use the following functions for columns: o Move using Drag&Drop o Make wider or narrower o Select o Sort  The list can be sorted according to several fields at once (for example, if an order list should be sorted first by cost center and then by date within the cost center).  You can also change lists using a customer exit (for example, to add headings or change print parameters). 

(C) SAP AG

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6.7.5 Maintenance Order: Multi-Level Order Lists 902045

C1-B02

Filter station

P-1000

Electric pump

0010

Renew seals and pressure caps

0020 615000 Estimated 0.00 

Order - Repair electric pump

100-431

Oil seal

200-801

Pressure cap

Renew electric cables Internal processing - Internal allocation Planned

Actual

345.80

0.00

SAP AG 1999

When you create a multi-level order list, you receive a color-coded list containing all the groups of data that you requested on the selection screen. This provides you with an overview of all the important data contained in the maintenance order.  To process the list further, you can now also:  Display the color legend  Show and hide data  Select the fields, which you want to display in the list, based on the selection criteria chosen on the selection screen  Display the master record for each technical object in the list  Display the resources for each maintenance order required in the list  Download the data for maintenance orders in the list 

(C) SAP AG

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6.7.6 Resource Planning: Availability check

Material withdrawal for cost center

Plant stock

Stock transfer to other plant Goods receipt from purchase order

Goods receipt from internal production Maximum quantity of ATP

Stock profile

Safety stock Today 

Requirement date

SAP AG 2001

When you schedule stock materials to execute order operations, the system can check in a single step whether all the materials in the maintenance order are available in sufficient quantities. You use the availability check function for this.  The system now performs an availability check for all the materials, which have been assigned to the maintenance order in its operations, in accordance with your system settings and entries in the material master records. The system informs you of the result in an online message. If there is a lack of availability, you can display an error log that contains detail data about the result of the check.  When you release a maintenance order, the system performs an availability check for planned materials, depending on your Customizing settings. If this check reveals that certain planned materials are not available in sufficient quantities, you may or may not be able to release the maintenance order, depending on your system settings. 

(C) SAP AG

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6.7.7 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

You can display information about the availability of materials, which have been planned for an order, in the material availability list. For non-stock items, the list enables you to see whether the date for the planned goods receipt (from a purchase requisition or purchase order) is sufficient to meet the earliest or latest start date for the operation. You can also see why it may not be possible to meet the deadline for a planned goods receipt. For items kept in stock, the quantity determined and confirmed by the material availability check is compared with the quantity required. Note: The data in the list is not simulation data used to determine the most favorable start date. The list displays valid material availability for the order that the system has determined based on valid data. You can also flag individual order components as not relevant for planning. This means that no reservation or purchase requisition is generated from such a component. The availability list can be started within an order and from the list editing function for orders. If you call up the availability list from list editing, the hit list can be displayed at different summation levels (order level, orders with operations, orders with operations and material items).

(C) SAP AG

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6.7.8 Order Release

Effects of order release:

Reservation effective, can be withdrawn Papers can be printed Confirmation possible Goods movement possible



SAP AG 1999

When you release a maintenance order, the system checks the availability of material, production resources/tools, and the necessary permits. At the time of release (at the latest), material reservations become relevant for materials planning, materials can be withdrawn, and purchase requisitions generated.  The following activities can only be performed after you have released the order:  Print shop papers 



Withdraw material



Post goods receipts



Enter time confirmations



Complete task

You can release a maintenance order immediately after it has been created. This option is available for maintenance orders created automatically by the system, in other words, for maintenance orders created:  Using a maintenance plan  From a maintenance notification  To enable these orders to be released upon creation, the indicator "Release immediately" must be set for the required order types by the system administration in Customizing. 

(C) SAP AG

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6.7.9 Maintenance Order: Printing

Maintenance order

Fax transfer

Job ticket

Material withdrawal slip

Control ticket Confirmation slip

Pick list Time ticket Object list





   

 

SAP AG 1999

Job ticket: The job ticket is a document which gives the person executing the maintenance work a complete overview of the order. If your system is connected to the Document Management System, you can also print graphics (for example, engineering/design drawings of the technical system concerned) on the job ticket. Operation control ticket: Shows the maintenance engineer responsible a complete overview of the maintenance order. It also contains information about permits. Material pick list: Shows the warehouse clerk which materials have been planned for each operation in this order. Object list: Shows an overview of the objects (technical objects, notifications) involved in the order. Time ticket: Contains the planned work and duration, and is only printed for operations with the corresponding control key. For each worker involved on the order, time tickets are printed in the numbers specified for each operation. The worker can enter the time required to execute the operation on the time ticket that will be entered in the R/3 System later. Confirmation slip: Used by the worker to enter their work times for each operation. Material withdrawal slip: Authorizes the person executing the maintenance work to take the materials required for the order from the warehouse. One material withdrawal slip is printed for each material component.

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6.7.10 Maintenance Order: Delta Printing

Function:

Individually Several orders at once

Original printout / reprint / delta print

Print log

Status "Printed"



SAP AG 1999

You have the option of printing all the shop papers not yet printed for a maintenance order at once. This is delta printing. You can only use delta printing if your system is set up accordingly. The required Customizing setting must be made for this by your system administration.  Result of delta printing:  Only new operations (operations which have not been printed) appear on the job ticket and operation control ticket.  Time tickets are only printed if they do not yet have the status "Printed".  Components are only printed if they have not been printed before on a component slip (for example, the material withdrawal slip).  The printouts are identified as delta printouts.  As soon as you have printed shop papers for a maintenance order, the system automatically assigns the status "Printed" to the order and creates a print log. You can use the print log to determine:  Which papers have already been printed for a maintenance order  Who initiated the printing  When the papers were printed 

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6.7.11Exercises Unit: Corrective Maintenance Topic: Scheduling of Maintenance Tasks

At the conclusion of these exercises, you will be able to:  Select lists of maintenance orders  Perform an availability check for resources  Release orders  Print orders The maintenance planner is responsible for ensuring that the orders are processed in time. The planner must ensure that the materials are available, shop papers printed, and order released for processing.

3-1-1 Select all orders either outstanding or in process for order types PM01 and PM02 up to the current date. Show the planned and actual costs in the selection result. How do you proceed? __________________________________________________________ __________________________________________________________ __________________________________________________________

3-1-2 Sort the selection result according to order type (first criterion) and basic start date (second criterion). How do you proceed? Create a totals line for the planned and actual costs and generate a subtotal for each order type. How do you proceed? __________________________________________________________ __________________________________________________________ __________________________________________________________ 3-2-1 Select all your maintenance orders. Which selection criteria do you choose? (C) SAP AG

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How can you save these selection criteria for future selections? __________________________________________________________ __________________________________________________________ __________________________________________________________

3-2-2 Configure the columns ‘Equipment’, ‘Notification’ and ‘System status’ in the resulting hit list. How do you proceed? How can this display variant be saved and defined as the standard variant? __________________________________________________________ __________________________________________________________ __________________________________________________________

3-3

Complete Availability Check Check the availability of the required materials for your order. Which menu path do you choose to check the availability of all the materials at the same time? __________________________________________________________ __________________________________________________________ __________________________________________________________ What system message do you receive? __________________________________________________________ Which entries are shown in the availability log? __________________________________________________________ __________________________________________________________ __________________________________________________________

3-4

Overview of Materials in Orders Obtain an overview of the situation concerning materials in your orders. Which orders have missing parts?

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How can you obtain an overview of the current situation regarding stock and nonstock materials for all your orders? __________________________________________________________ __________________________________________________________ __________________________________________________________

3-5

Order Release Release all your outstanding orders. How do you proceed? __________________________________________________________ __________________________________________________________ __________________________________________________________ What are the consequences of the order release? __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________

3-6

Shop Paper Printing

3-6-1 Printing Orders with Print Preview Display the print preview for one of your orders, and print it on the default printer. Which shop papers are printed? __________________________________________________________ __________________________________________________________ __________________________________________________________

3-6-2 Print Log Call up your order again, and display the print log. Which entries are included? __________________________________________________________ __________________________________________________________ __________________________________________________________

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6.7.12Solutions Unit: Corrective Maintenance Topic: Scheduling of Maintenance Tasks

3-1-1 Selection: SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  List of Orders  Change Set statuses 'Outstanding' and 'In process', set order types from PM01 to PM02, delete 'From' date for period; execute Display / Sort fields: Settings  Display variant  Current: Select 'Total planned costs' and 'Total actual costs’ button '' and 'Copy'

3-1-2 Sorting: Select OrdType and take from ‘Basic start’ column; Select columns ‘OrdType’ and ‘Basic start’ and press button for sort ascending >> They are sorted according to order type and within order type according to basic start date. Totals row: Select ‘Total planned costs’ column and press ‘Total’ button In the column ‘OrdType”, position the cursor on order type “PM01” and press button “Subtotal”. >> A dialog box appears >> Activate subtotal for order type (set checkmark) >> A subtotal for planned costs is created for each order type at the end of the table for the respective subtotal.

3-2-1 For example: Entered by LO100-xx or planner group I## and period from start of course until end of course Save the selection variant: (C) SAP AG

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Settings  Variants  Save as variant Variant name: U_LO100-## (this is thereby the standard variant for user LO100-##) Description: For example, my orders

3-2-2 Settings  Display variants  Current Select equipment, notification and system status from the hidden fields and copy them to the active area Settings  Display variants  Save as variant Enter variant name and description Settings  Display variants  Management Set selection (green checkmark) in the ‘Initial variant’ field 3-3 Change order: Order  Functions  Availability  Material Message: All checked materials in order 9020xx are available Availability log: Goto  Logs  Material availability Information message CO282: No missing material for order 9020xx

3-4

Overview of Materials in Orders SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  List Editing  Change Use the same selection criteria as for 1-1; select all orders You can select several lines in the order list (selection hit list) by clicking on the desired line while simultaneously pressing the SHIFT button (select block) or CTRL button (select several individual notifications). Goto  Mat. avail. list There are no missing parts for orders with a green traffic light symbol, that is, both stock and non-stock materials are available.

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Before the “Availability list” function can be used, at least one regular availability check must have been executed for the order.

3-5

Order Release Field name or data type

Values

Options

- List editing: Select orders and press ‘Release’ symbol - Change order: Order  Functions  Release - Change order: Symbol 'Put in process' - Customizing setting for automatic order release

Field name or data type

Values

Consequences

- Order can be printed - Reservations become effective - Material movements are possible - Notifications can be entered

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3-6-1 Printing Orders with Print Preview Field name or data type

Values

Shop papers

Control ticket Material withdrawal slip Job ticket Material pick list Order object list Time ticket

3-6-2 Print Log Field name or data type

Values

For each printed shop paper

Output device Delta printing Copy User Date Time

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6.8 Corrective Maintenance: Execution of Maintenance Tasks

 Notification of maintenance requirements  Planning of orders  Scheduling of maintenance tasks  Execution of maintenance tasks  Completion of notifications and orders

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6.8.2 Cycle for Corrective Maintenance Phase

1 2

Contents

Notification Planning

Roles

Technical Due Technical object object Due date date Description DescriptionMalfunction Malfunction

Production Production worker worker Maintenance Maintenance planner planner

Work Work to to be be performed performed Material Material Internal/external Internal/external resources resources

Maintenance Maintenance planner planner

3

Scheduling

Order Capacity Order release release Capacity leveling leveling Printout Availability Printout Availability check check

Maintenance Maintenance supervisor supervisor

4

Execution

Planned/unplanned material withdrawal External procurement

Technician Senior storeperson

5

Completion

Time Order Time confirmation confirmation Order settlement settlement Technical Technical completion completion Technical Technical confirmation confirmation

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



SAP AG 2001

The execution phase (step 4) involves the withdrawal of spare parts from the warehouse and the actual execution of the order.

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6.8.3 Material Withdrawal

Pick list

Planned material withdrawal Unplanned material withdrawal





  

 

Maintenance order

SAP AG 1999

Workers withdraw materials from the warehouse to perform maintenance tasks. There are two types of withdrawal: - Planned withdrawal of stock material - Unplanned withdrawal of stock material Materials can also be procured externally (see External Procurement of Non-Stock Material). You can display the goods movements that take place for a maintenance order. From the maintenance order, you can display:  Any goods receipts for purchase orders for the order  Which planned goods issues have taken place for the order  Which unplanned goods issues have taken place for the order The data displayed in the list is defined by your system administration in Customizing. Customizing settings can be changed later. You have to restructure the link list using report RIAUFM00.

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6.8.4Exercises Unit: Corrective Maintenance Topic: Execution of Maintenance Tasks

At the conclusion of these exercises, you will be able to:  Make planned withdrawals of material  Make unplanned withdrawals of material

You must first withdraw the required materials when performing a task.

4-1

Planned Material Withdrawal Withdraw the reserved material with reference to the order number. How do you proceed? ____________________________________________________________ ____________________________________________________________ Which materials do you withdraw? Material

Planned quantity

Quantity withdrawn

Which document number is assigned? ____________________________________________________________ ____________________________________________________________ 4-2

Unplanned Material Withdrawal Make an additional, unplanned withdrawal of material for one of your orders.

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Movement type

261

Plant

1000

Storage location

*

Which material have you withdrawn? ____________________________________________________________ ____________________________________________________________ Which document number is assigned? ____________________________________________________________

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6.8.5Solutions Unit: Corrective Maintenance Topic: Execution of Maintenance Tasks

4-1

Planned Material Withdrawal SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Goods Movement  Goods Movement Field name or data type

Values

Movement type

261

Plant

1000

Storage location

0001

Button 'To order....' > Enter order number Material

Planned quantity

Quantity withdrawn

100-400

1

2

100-600

2

2

Document number: 4900xxxx

4-2

Unplanned Material Withdrawal

Field name or data type

Values

Movement type

261

Plant

1000

Storage location

0001

Then data release (not: button ‘To order...’) Field name or data type (C) SAP AG

Values LO100

63

Material

For example, 100-100

Order number

Your order number

Document number: 4900xxxx

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6.9 Corrective Maintenance: Completion of Notifications and Orders

 Notification of maintenance requirements  Planning of orders  Scheduling of maintenance tasks  Execution of maintenance tasks  Completion of notifications and orders

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6.9.2 Cycle for Corrective Maintenance Phase

1

Contents

Notification

2

Planning

Roles

Technical Due Technical object object Due date date Description DescriptionMalfunction Malfunction

Production Production worker worker Maintenance Maintenance planner planner

Work Work to to be be performed performed Material Material Internal/external Internal/external resources resources

Maintenance Maintenance planner planner

3

Scheduling

Order Capacity Order release release Capacity leveling leveling Printout Availability Printout Availability check check

Maintenance Maintenance supervisor supervisor

4

Execution

Planned/unplanned Planned/unplanned material material withdrawal withdrawal External External procurement procurement

Technician Technician Senior Senior storeperson storeperson

5

Completion

Technician Time confirmation Technical completion Techn confirmation Maintenance supervisor

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



SAP AG 2001

After the work has been completed, the actual time required is confirmed in step 5. Technical confirmations are also entered to record the repair and condition of the technical system. The order is settled in Controlling.

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6.9.3 Order Completion Confirmation: Times / Activities

Times Individual entry Collective entry Overall completion confirmation Time sheet (CATS)

Activities Activity reports Overall completion confirmation Confirmation texts

Measurements/counter readings













SAP AG 2001

There are three different ways to confirm the time required for work on a maintenance order:  Individual entry of times for each order operation  Collective entry by direct entry or using an operation list  Overall completion confirmation: times, activities, measurement values, and others on a collective screen  Entry using the cross-application time sheet (CATS) Once completion confirmations for operations/sub-operations in a maintenance order have been entered, the system automatically assigns the status "Partially confirmed" to these operations/suboperations, if no setting has been made in Customizing that a final completion confirmation should be proposed automatically. As soon as all the operations/sub-operations in a maintenance order have been completely confirmed, the order itself is assigned the status "Finally confirmed". There is always a risk of completion confirmations being assigned to the wrong operations/suboperations or entered with the wrong data. The system therefore allows you to reverse completion confirmations if required. The activities performed are entered as maintenance notifications with notification type "Activity report" and assigned to the corresponding order. Alternatively, confirmation texts can be entered with confirmations of time. However, these are not as easy to structure and analyze as activity reports. Measurement readings are entered as measurement documents for the reference object.

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6.9.4 Technical Confirmation (1)

Classification of defects

Causes of damage

Activities

Tasks

Damage

System availability



SAP AG 1999

When technical objects are maintained, and detailed technical data recorded, it forms the basis for subsequent evaluation. Technical data can provide information on:  Cause of damage (classification of defects, causes of damage)  Work executed (activities, tasks)  Exact location of damage and symptoms (damage)  Machine downtimes and system availability during and after the maintenance task (system availability)  You use maintenance notifications to enter this data for the technical objects identified in the object list of the maintenance order.  When you complete the maintenance notification, the data is transferred to the notification history. It is a part of the maintenance history and contains information for each technical object about damage, malfunctions, causes, findings, and maintenance work performed. 

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6.9.5 Technical Confirmation (2)

Order 901760

Object list 901760

M-1000-N001 M-1000-N002

Notification 100087 Object M-1000-N001 Damage: Oil loss Cause: Overload

Notification Activities: 100088 Pump checked Object

Seals renewed Equipment M-1000-N002 Damage:

orLeakage Functional locations Cause: Overload or Notifications Activities: Pump checked Seals renewed



SAP AG 2001

When you technically confirm technical objects, which have been assigned directly to the order in the object list, you create a new maintenance notification for each object.  Existing maintenance notifications: If one or more maintenance notifications have already been assigned to the order, you can access the notification in the following ways:  From the maintenance order  From the object list 

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6.9.6 Overall Completion Confirmation Completion confirmation Order 901760

Operation 10

2h

Operation 20

3h

Time

Material 100-501

2 Pc

100-605

2 Pc

Measurement documents

Measuring point 43110.1 bar

Counter 932





5834 L

+ activities, tasks, and services

SAP AG 2001

The overall completion confirmation enables you to confirm not only working times, but all the relevant details for an order on a single screen, configured to suit your individual requirements. Time confirmations and technical confirmations can therefore be processed in the same way.

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6.9.7 Maintenance Order: Technical Completion (1)

Notification 10.000.123

Order 901760 Object list 901760 Technical completion Reference date: Reference time: Notifications:

MMAB

Notification 10000123 X

Notification 10000124

Notification 10.000.124

MMAB



SAP AG 2001

You have two options:  Complete the maintenance order and notification separately  Complete the maintenance order together with assigned notifications  To complete the order and notification together, there must not be any outstanding tasks in the notification. 

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6.9.8 Maintenance Order: Technical Completion (2)

Order 901760

Limited ability to change order Status 'Technically completed' Determine location and account assignment data Create settlement rule Set deletion flag for purchase requisitions Close open reservations Close open capacities



 





   

SAP AG 2001

The maintenance order obtains the status 'Technically completed'. In other words, the maintenance work required for this order has been completed. The maintenance order can then only be changed online as follows:  It can be locked or unlocked.  The deletion flag can be set. The location and account assignment data specified for the maintenance order is fixed and can no longer be changed. However, the order can still receive costs, for example, invoice receipts for materials delivered and consumed. If you have not maintained a settlement rule for the maintenance order, it is created automatically by the system. If this is not possible owing to missing data, the system directs you to where the settlement rule can be maintained (see also settlement rule). All open purchase requisitions that still exist for the maintenance order are given a deletion indicator. All open reservations that still exist for the maintenance order are closed. Capacities that have been planned for the maintenance order and that are still open, are closed. The order data and the data from maintenance notifications and usage histories are available in the maintenance history and can be used for the evaluation of past work and the planning of new work.

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6.9.9 Reverse Technical Completion

Order 901760 Order becomes modifiable again Status REL (Released) is set

TECO

Location and account assignment data are re-copied from the object Open purchase requisitions are recompiled Open reservations are recompiled Open capacities are recompiled



 

SAP AG 2001

You can reverse the status TECO (technically completed) if required. The order is given the status that it had before the technical completion, in other words, capacity requirements and reservations are restructured and the deletion indicator is reset again for unconverted purchase requisitions.

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6.9.10 Maintenance Notification: Complete

Notification 10 000 264 Prerequisites: All data available and correct ? No outstanding tasks

Consequences: Notification can no longer be changed Reference time fixed Status 'Notification completed'



SAP AG 2001

Before you complete a maintenance notification, check whether:  All data, which refers to the reference object for the maintenance notification, is available and correct.  All the relevant item data is available and correct.  All the relevant task data is available and correct.  All tasks have been completed or released; there are no more outstanding tasks.  All technical data related to the breakdown and availability of the technical system is available and correct.  When you complete a maintenance notification, the following occurs:  The reference time is defined: The system proposes a time based on the data in the maintenance notification, but you can overwrite it. The reference time is the date and time, at which the maintenance notification is entered in the history with the location and account assignment data then valid for the reference object. In other words, the system enters the maintenance notification in the history with the exact location and account assignment data, which was valid for the reference object at the reference time.  The maintenance notification is locked for changes, which means that you can no longer change notification data.  The notification is assigned the status "'Notification completed". 

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6.9.11 Action Log

Who changed what and when? Causes of damage Texts

Maintenance order Maintenance notification

Address Purchasing data

Malfunction data Technical objects Dates 

Sales data Priorities

Account assignment data

Damage

SAP AG 1999

Changes to notifications, orders, equipment, and functional locations are displayed in chronological order in an action log. This enables you to track who has changed the data or status of specific fields and when they were changed.  To use this function, the respective change documents created (for each object, status, or partner) must be active. 

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6.9.12 Document Flow

All document types created for maintenance order can be displayed: - Notification - Completion confirmation - Goods movement - Purchase requisition - Purchase order

Maintenance order



SAP AG 1999

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6.9.13 Corrective Maintenance: Summary

You are now able to:  Use the maintenance notification to register a

maintenance requirement  Plan orders (create operations, reserve material, enter

data in the object list, costing, budgeting)  Schedule and process orders (release the order, check

for availability of resources, print the order, dispatch capacities)  Make planned or unplanned withdrawals of material from

the warehouse for performing maintenance tasks  Enter actual times and technical confirmations  Complete the order together with the notification



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6.9.14Completion

of Order and Notification: Exercises

Unit: Corrective Maintenance Topic: Completion of Order and Notification

At the conclusion of these exercises, you will be able to:  Enter time confirmations  Enter technical confirmations  Technically complete an order  Settle an order If the maintenance task has been technically completed, the working times are entered in the time confirmation, and the activities, damage, and causes of damage entered in the technical confirmation. The order and notification are then completed. The order is still settled to a receiver.

5-1

Confirm the order you last processed using the overall completion confirmation function. Which menu path do you use? How can you adapt the confirmation screen? ____________________________________________________________ ____________________________________________________________

5-2

What other options for time confirmation do you know? ____________________________________________________________ ____________________________________________________________

5-3

Technical completion confirmation in an existing maintenance notification

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Enter a technical confirmation for the maintenance order that was created based on a maintenance notification (maintenance request). How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Enter the following, if necessary: - General technical description - Damage - Cause of damage - Activities - Tasks Which data have you entered?

Damage Cause of damage Activities (code group/code)

Tasks (code group/code)

If tasks are entered in the notification, these always refer to work still to be executed. The notification thereby obtains the system status OSTS. Tasks must always be marked as finished before the notification can be completed.

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5-4

Technical confirmation as a new maintenance notification Enter a technical confirmation for the maintenance order that you entered directly. How do you proceed? ____________________________________________________________ ____________________________________________________________

Enter the following, if necessary: - General technical description - Damage code - Cause of damage - Activities - Tasks Which data have you entered?

Damage code Cause of damage Activities (code group/code)

Tasks (code group/code)

Save the maintenance notification. Which number is assigned to the notification? ____________________________________________________________ ____________________________________________________________ (C) SAP AG

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Is the maintenance notification number transferred to the maintenance order?  No

5-5

 Yes

Technical Completion Complete all your maintenance orders and notifications. Use the list editing function for this. Which criteria do you enter to select all your maintenance orders? ____________________________________________________________ ____________________________________________________________

5-5-1 How are maintenance orders completed technically? ____________________________________________________________ ____________________________________________________________

5-5-2 Complete the maintenance notifications at the same time. What do you have to do? ____________________________________________________________ ____________________________________________________________

5-5-3 What are the consequences of the technical completion of a maintenance order? ____________________________________________________________ ____________________________________________________________

5-5-4 What are the consequences of the completion of a maintenance notification? ____________________________________________________________ ____________________________________________________________

5-6

Status Which status does the order have after the technical completion?

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____________________________________________________________ ____________________________________________________________

5-7

Cost overview Switch to the cost overview. Which value categories have estimated, planned, and actual costs?

Value category

(C) SAP AG

Estimated costs

Planned costs

LO100

Actual costs

82

6.9.15Completion of Order and Notification: Solutions Unit: Corrective Maintenance Topic: Completion of Order and Notification

5-1

Overall completion confirmation: SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Entry  Overall Completion Confirmation A profile can be selected using Extras  Settings which determines the layout of the confirmation screen. The profiles are defined in Customizing. After the order number has been entered, release the data >> All the operations for the order are copied into the confirmation list. If material withdrawals should also be posted in the overall completion confirmation, proceed as follows: In the time confirmation, select the corresponding operation and press the magnifying glass symbol in the same line (data for the operation). >> Materials which belong to the operations are displayed in the goods movement (either subscreen or pushbutton).

5-2

Time confirmation options: SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Entry  Individual Time Confirmation Confirmation of an order with an operation SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Entry Collective Time Confirmation  With/Without Selection Confirmation of several orders with more than one operation, either from an empty list or from a selection screen.

5-3

Technical completion confirmation of an existing maintenance notification SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change Button “Notification”

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or SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Notification  Change Enter notification number Field name or data type

Values

Damage

For example, PUMP/100 1000

Cause of damage

For example, PM02 1001

Activities (code group/code)

For example, pump/101 2003 For example, pump/101 2004 For example, pump/101 2006

Tasks (code group/code)

5-4

For example, PM01/100

Technical confirmation as a new maintenance notification SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change Button 'Notification', enter the notification type or button 'Objects', select entry, symbol 'Create notification' Field name or data type

Values

Damage

For example, PUMP/100 1000

Cause of damage

For example, PM02 1001

Activities (code group/code)

For example, pump/101 2003 For example, pump/101 2004 For example, pump/101 2006

Tasks (code group/code)

For example, PM01/100

Notification number: 10000xxx Is the maintenance notification number transferred to the maintenance order?

 Yes 5-5 (C) SAP AG

Technical Completion LO100

84

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  List of Orders  Change For example, entered by LO100-xx or planner group I## and period from ‘start of course’ until ‘end of course’

5-5-1 Selecting Orders Order  Completion  Complete (technically) or within an order, Button Complete technically

5-5-2 Completing a Notification: In list editing: Button Incl. Notification within an order, select ‘Complete notifications’ field in dialog box for reference time

5-5-3 Field name or data type

Values

Consequences of order completion

- No more changes possible - Status TECO - Outstanding reservations are cleared - Outstanding capacity loads are removed - Outstanding purchase order requests are assigned a deletion flag

5-5-4 Field name or data type

Values

Consequences of notification completion

- Notification can no longer be changed - Status NOCO

5-6 (C) SAP AG

Status LO100

85

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change System Status

5-7

Field name or data type

Values

TECO

Technically completed

CNF

(Finally) confirmed

PRT

Printed

SETC

Settlement rule created

MACM

Material committed

PRC

Pre-costed

Cost overview SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change Costs tab page

(C) SAP AG

Value category

Estimated costs

Planned costs Actual costs

Internal material

250,00

309,00

412,00

External material

80,00

50,00

75,00

Internal labor

850,00

713,06

475,38

LO100

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7 External Services

Contents:  Basics of external services  External services as individual purchase order  External services with external company work centers  External services as service items



SAP AG 1999

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7.2 External Services: Unit Objectives

At the conclusion of this unit, you will be able to:  Trigger an individual order for external services and describe the subsequent processing steps  Represent external companies that you use regularly in the same way as internal personnel  Set up service specifications, include them in a maintenance order, and accept the services performed



SAP AG 1999

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7.3 Course Overview Diagram

Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook



SAP AG 2001

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7.4 External Services: Business Scenario  IDES hires external companies to perform work, for which the required capacity and skills are not available internally.  IDES distinguishes between short-term requirements, which can be processed using individual purchase orders, and long-term relationships with vendors, which can be represented using external company work centers.



SAP AG 1999

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7.5 External Services: Basics of External Services

 Basics of external services  External services as individual purchase order  External services with external company work centers  External services as service items



SAP AG 1999

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7.6 How is an External Service Triggered?

External company work center

Individual purchase order

Control key PM01 External processing = " " Service = " "

Required

Control key PM02

Purchase requisition



 

Free

Capacity load

External processing = + Service = " "

Purchase requisition Service items

Control key PM03

Service item

Available

External processing = + Service = X

SAP AG 1999

The external assignment of services is triggered in the SAP system using the control key. The control key determines the type of external service assignment:  PM01: The external assignment is processed using an internal order, in the same way as for internal work centers (see "External Services with External Company Work Centers").  PM02: The external assignment is processed using a purchase requisition and a standard individual purchase order (see "External Services as Individual Purchase Order").  PM03: The external assignment is processed using service items or service specifications and subsequent service entry.

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7.7 Outsourcing Individual operations

Purchase requisition

Maintenance order Operation 10

PM02

Operation 20

PM01

Purchase requisition

Sub-operat. 20 10 PM01 Sub-operat. 20 20 PM02 Operation 30

PM01

Complete order

Purchase requisition

Maintenance order Operation 10 PM02



SAP AG 2001

To assign part of the work in a maintenance order to external companies, you can use operations and sub-operations. This allows you to share maintenance order operations/sub-operations between internal and external work centers.  In certain cases, you may need to assign a complete maintenance order to an external company. To do this, you create a maintenance order with only one operation, which you assign to an external company.  External services can be assigned in two ways: - as vendor master records - as an external work center (see topic "External services with external company work centers") 

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7.8 External Services: External Services as Individual Purchase Order

 Basics of external services  External services as individual purchase order  External services with external company work centers  External services as service items



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7.9 Individual Purchase Order: Phases and Roles Phase

1

Order

2

Purchase order

3

Goods receipt

4

Technical completion

5

Invoice





 

  

Contents

Roles

Plan order Automatic purchase requisition

Maintenance planner

Create purchase order

Purchaser

Book goods receipt (and enter service)

Maintenance supervisor

Technically complete the order

Maintenance supervisor

Invoice

Invoice verification clerk

SAP AG 2001

When external services are planned in a maintenance order, a purchase requisition is automatically triggered in the background. You find the number of the purchase requisition on the detail screen for external processing of the operation/sub-operation. The purchasing department (or maintenance planner) converts the purchase requisition into a purchase order. You do not confirm external services in the same way as normal time confirmations; you enter them like a service confirmation as a goods receipt for the purchase order. The service is therefore given the value of the purchase price and entered in the accounts for Financial Accounting. The maintenance order used to order the service is debited with this value. In the maintenance order, you can see on the external processing screen for the operation whether a goods receipt has been posted for the purchase order: You can see the posted goods receipt quantity in the corresponding field. The vendor invoice usually arrives after the delivery. For this reason, the offsetting entry is put on a clearing account and automatically written off upon invoice receipt. Any differences between the purchase order value and invoice value are subsequently debited from the order or credited to it.

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7.10 External Assignment Based on Hours or Fixed Price

Hours

Purchase requisition Maintenance order Operation 010 20h 1h = $ 85.00

Fixed price

Purchase requisition Maintenance order Operation 010 $1 $ 5000



SAP AG 2001

You can assign an external operation on an hourly basis. The number of hours and respective unit and price per hour (if known) are entered here on the external data screen for the operation.  However, you can assign an external operation based on a fixed price. For this, 1 SU (= service unit) for a fixed price is entered on the external data screen for the operation. 

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7.11 Creating an Individual Purchase Order Maintenance order Purchase requisition

Purchase order 1 2

Vendor



      

SAP AG 1999

A purchase order is usually created by the purchaser and is therefore not part of Plant Maintenance. The function "Create purchase order" is part of Materials Management (MM). A purchase order can contain items for stock material, consumable material, or services. Multiple account assignment for one item is possible. The goods receipts for this item are entered without values. Schedule lines can be used for a purchase order item, in which to inform the vendor about the different delivery times. For the function Create purchase order for known vendor, the vendor is specified on the initial screen. You can refer to a purchase requisition within this function. The function Create purchase order using purchase requisitions can only be performed for purchase requisitions, to which a source of supply is assigned. For the function Create purchase order with unknown vendor, the person requesting the service specifies what should be procured. That person can then perform a source determination. If the system determines a source of supply, a purchase order is created; otherwise, a purchase requisition is created.

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7.12 Order Status for Goods Receipt

Goods receipt

Order 901875

Order 901875 External service 12 h Final delivery = 

Operation 010 External service Status = EODL

No "Inward delivery completed" indicator



Status = EOPD

SAP AG 2001

After a goods receipt for an external operation is posted, the status "External operation partially delivered (EOPD)" is set in the external operation.  If you have set the final delivery indicator on the goods receipt for an external service, the status "External operation delivery completed (EODL)" is set. 

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7.13 Invoice Verification

Net costs Purchase order 1

Company

Goods receipt

2

Order 901760

MDO

Invoice

0010 Operation

? = Invoice verification





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The vendor invoice usually arrives after the delivery. For this reason, the offsetting entry is put on a clearing account and automatically written off upon invoice receipt. Any differences between the purchase order value and invoice value are subsequently debited from the order or credited to it.

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7.14 External Services: External Services with External Company Work Centers

 Basics of external services  External services as individual purchase order  External services with external company work centers  External services as service items

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7.15 External Work Center: Phases and Roles Phase

1

Order

2

Completion confirmation

3

Technical completion

4



Invoice

Contents Plan order with external work center in operation

Time confirmation (credit external firm cost center

Technically complete the order

Invoice debit external firm cost center

Roles Maintenance planner

Maintenance supervisor

Maintenance supervisor

Invoice verification clerk

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7.16 Prerequisites Activity type planning 2000 Cost center Activity type

4010 4010 4010 4050 4100 4100 4100 4200 4200 4200 4200

Work center FR01 Quick & Co. Cost center 4050 Control key PM01 Activity type F01

……..

Purchase order M No. 45000125 1

Quick

1410 1411 1412 F01 1411 1412 1420 MST FST RUE PER

Rate

32.50 33.80 75.00 62.70 33.80 55.75 33.90 69.00 12.00 45.00 80.00

……..

Cost center 4050 Quick & Co.

01/01/98 - 06/30/98

150 manual worker hours at $ 62.70 Account assignment: Cost center 4050 

  

 



SAP AG 2001

To process maintenance orders for external companies using external company work centers, the following master data prerequisites must first be created: You set up a cost center for all external companies together or one for each external company. You configure one or more activity type master records, depending on whether:  You are using one or more cost centers  The external company has one charge rate or several different ones For the current fiscal year, you plan the rate for the cost center(s) and activity type(s). You set up a work center for the external company that has:  Similar default values to internal work centers (for example, control key PM01)  A link to the cost center and activity type You release a purchase order to the external company (vendor) that has:  Been assigned to the cost center of the external company  A certain validity period  The rate for the activity type as item price

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7.17 Set Up Order Order 901760

Renew electric cables Work Center: FR01 Quick & Co. 0010 PM01 Electric cables...

Control key PM01 12 h

In other words, like an internal order 



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Standing orders are created and processed in the same way as internal orders.

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7.18 Confirm Order Order 901760

Renew electric cables Work center: FR01 Quick & Co. 0010 PM01 Electric cables...

Actual time

10 h

Date 01/20/98

In other words, like an internal order 



SAP AG 2001

Standing orders are confirmed in the same way as internal orders.

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7.19 Settling a Maintenance Order

AM asset CO / PP / PM order Project Sender cost center 4050

Receiver cost center

Credit

Debit

Settle activity TO 901956 10 h $ 627

Settled activity 10 h $ 627

Maintenance order 901956 Debit

Activity COST 4050 10 h $ 627 

Settlement

Settled activity 10 h $ 627

SAP AG 1999

When you use an external company, the amount involved is credited to the cost center of the external company and debited against the maintenance order. The credit entry is made using the time confirmation.  The costs temporarily collected on the maintenance order are forwarded to the receiver cost center specified in the settlement rule of the maintenance order (for example, equipment cost center).  To settle a maintenance order, the following prerequisites must be fulfilled:  The maintenance order must have been released.  The maintenance order must have the status "Settlement rule created".  Costs not yet settled should be accumulated on the maintenance order. 

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7.20 Billing Document and Controlling

Sender cost center 4050 Quick & Co. Debit Invoice 50224 4,389

Credit Settle activity TO 901956 627

Quick & Co.

Invoice 50224

MDO

Maintenance order 901956

Purchase order no. 45000125 Period 01/01/98 - 01/31/98 Order ..... Order ..... Order ..... Order 901956 Order ..... Order ..... Order ..... Total:



Debit Activity COST 4050 10 h $ 627

10 h $ 627

70 h $ 4,389

SAP AG 1999

Invoices are not received for every single activity, but periodically (for example, monthly). The total invoice amount contains the value of all the services executed since the last invoice was created. You can also display the list of orders executed as additional information.  The invoice is assigned to the cost center of the external company (not to the individual orders).  The cost center of the external company must be balanced, in other words, the total of all credited amounts (maintenance orders) = the total of all debited amounts (billing documents).  

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7.21 External Services: External Services as Service Items

 Basics of external services  External services as individual purchase order  External services with external company work centers  External services as service items



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7.22 Service Procurement: Phases and Roles Phase

1

Order

2

Purchase order

3

Service entry

4

Technical completion

5

Invoice



Contents

Roles

Plan order Automatic purchase requisition

Maintenance planner

Create purchase order

Purchaser

Service entry for purchase order

Maintenance supervisor

Technically complete the order

Maintenance supervisor

Invoice

Invoice verification clerk

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7.23 Service Master Record

Service no. 1540 - Texts - Units of measure - Prices Service master record

PM Plant Maintenance

PS Project System

MM Procurement

Applications 

  

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A service master record contains the service description and unit of measure, for example, hours. You can use the conditions to assign a price to each service master record. This data can be drawn from different SAP application components.

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7.24 Model Service Specifications

MODEL FOR PIPE LAYING 01 Preparatory work 02 Laying of main pipe 100002 Transport steel pipe 100003 Laying of steel pipe

Service masters with numbers

100004 Special wiring

03 Compression trials

04 Supply pipes



SAP AG 2001



You can schedule services in a maintenance order as individual service master records (service numbers) or using model or standard service specifications.



Model service specifications are used to store frequently used service specifications. They form part of the service master data and are therefore maintained in Materials Management.



This form of storage is suitable for all services, which you want to use repeatedly in a particular combination for different procurement operations.



For example, you can store all services, which are required for different pipe laying work (if necessary, grouped according to service areas), in a set of model service specifications "Pipe laying work" and use these model service specifications again later. This enables you to reduce the work required to create purchasing documents considerably.



You can use the model service specifications to assign services with the service selection function on the detail screen for the operation (processed internally or externally).

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7.25 Maintenance Order with Service Items Order 901760

Service specifications 01

Diggings 01

0010 PM03 Lay steel pipe

02 02

Lay steel pipe

Manual item in maintenance order

01 Tapping sleeve 02 Supply pipe

Item from service master data 

SAP AG 2001

You can plan the maintenance order, which contains service items, as a complete external order (possibly with its own order type) or as a combined order with internally processed operations and operations with service items.  The service item is generated in the operation using the control key. The control key carries the "Service" indicator (control key PM03 in the standard system).  If a control key is set in the operation using the service indicator, the tab page "Services" (used to access service specifications) is added to the detail screen for the operation.  Within the service specifications, you either schedule the required services using a service number (service master record) or by entering them manually without a service number. 

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7.26 Maintenance Order and Purchase Requisition

Order 901760

Purchase requisition

0010 PM03 Lay steel pipe

Service specifications 01

Digging 01 02

02

Lay steel pipe 01 Tapping sleeve 02 Supply pipe



 

SAP AG 1999

When you save or release the order, a purchase requisition is generated automatically. The purchase requisition contains the service specifications for the operation.

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7.27 Purchase Requisition and Purchase Order

Purchase requisition Purchase order

Service specifications 01

1

Digging

2

01

Service specifications

02 02

01

Lay steel pipe

Digging 01

01 Tapping sleeve 02

02 Supply pipe 02

Lay steel pipe 01 Tapping sleeve 02 Supply pipe



 

SAP AG 1999

In purchasing, a purchase order is created from the purchase requisition. The purchase order item copies the service specifications from the purchase requisition.

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7.28 Entry Sheets for Services Provided Service specifications in purchase order

Service entry sheets

Purchase order 1

Service entry sheet 03/12/98

2

Service specifications 01

Digging 01 02

02

Lay steel pipe 01 Tapping sleeve 02 Supply pipe



Service entry sheet 10 Dig 68 m³ 02/23/98 4 hrs 20 Tap 2 hrs Service entry sheet 10 Dig 30 Pipe 68 m³ 01/10/98 ..... 40 ....... 4 hrs 20 Tap ..... 50 ....... 2 hrs 30 Pipe 68 m³ 10 Digging ..... 40 ....... 4 hrs 20 Tapping sleeve ..... 50 ....... 2 hrs 30 Supply pipe ..... 40 ....... ..... 50 .......

SAP AG 1999

If a service has been provided by the external company, the service is entered using a service entry sheet, which is created with reference to the purchase order number.  The entry of the service performed is a function in Materials Management, but it can also be executed from Plant Maintenance using the completion confirmation.  Data such as service location, internal and external employees are first entered in the service entry sheet. You then enter the actual services provided in the service specifications, which are copied to the service entry sheet.  Once you have entered all the services, the service entry sheet must be accepted. 

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7.29 Cost Update in Order

Order 901760 Acceptance Acceptance document posted

! 0010 PM03 Lay steel pipe

Actualcosts costs Actual





SAP AG 2001

When the service entry sheet is accepted, the costs for the order are updated.

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7.30 External Services: Unit Summary

 For an individual external service, a purchase requisition is generated from the order. This is converted into a purchase order and a goods receipt is subsequently entered.  If you use external companies regularly, you should set up a work center, cost center, and framework order.  You plan services in the order for service processing. Service entry sheets are later created for these services.



SAP AG 1999

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7.31External

services as individual purchase order:

Exercises Unit: External services Topic: External Services as Individual Purchase Order At the conclusion of these exercises, you will be able to:  Configure a maintenance order for an external company that should trigger an individual purchase order  Perform further steps in external service processing Internal workshops cannot always provide the services required. These services must then be performed by external companies. Different processes can be used in PM depending on the type of activity to be performed or the relationship to the external company.

1-1

Maintenance Order with External Service Create an order (order type PM01) for your piece of equipment TEQ-##. Create an operation for this order. However, the task should now be performed by an external company. Which control key must you use? ____________________________________________________________ ____________________________________________________________ The external data screen appears. Enter the following data: Operation quantity:

1 PU

Price:

5000 per unit 1

Vendor:

1000 (optional)

The following data should appear automatically based on a setting in Customizing: Cost element:

417000

Material group:

007

Purchasing group:

008

Purchasing organization:

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Save your order. Which order number is assigned? ____________________________________________________________ ____________________________________________________________

1-2

Purchase Requisition Display your maintenance order again and determine which purchase requisition number has been generated. Which menu path do you use? ____________________________________________________________ ____________________________________________________________ What is the purchase requisition number? ____________________________________________________________ ____________________________________________________________ Double-click on the purchase requisition and determine the following data: Delivery date Desired vendor Fixed vendor Account assignment category Request date Goods receipt Invoice receipt Release date

1-3

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After the order has been created, what are the additional steps in processing external services based on an individual purchase order? (Note them down. As a further exercise, you can also execute these steps in the system.) ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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External services

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with external work centers: Unit: External services Topic: External services with external work centers

At the conclusion of these exercises, you will be able to:  Check the master data prerequisites  Process maintenance orders for external companies configured as work centers  Controlling You can represent an external company, with whom your company has a long-term agreement, in PM using an internal cost center and internal work center. Advantage: You no longer have to process service procurement using individual purchase orders.

2-1

External work centers A work center T-EX## is configured for the external company that should perform work for you. Display this work center. Which menu path do you use? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Determine the following data for this work center: Description Person responsible Standard value key Control key Cost center Activity type Formula key Purchase order number (*)

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Note: The purchase order number is stored as a characteristic in the classification of the work center.

2-2

Configuring a Maintenance Order Create a maintenance order for your piece of equipment TEQ-##. This maintenance order should be monitored by work center T-ME## and performed by work center T-EX##. Where do you enter work center T-ME## ? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Where do you enter work center T-EX##? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Put the order in process. Which order number is assigned? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

2-3

Further processing of the maintenance order Perform all the other steps required to process the maintenance order and write down what you have done. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

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External services as service items: Unit: External services Topic: External services as service items

At the conclusion of these exercises, you will be able to:  Configure a maintenance order, in which the contents of the work to be performed are described using service items  Display the relevant purchase requisition  Plan further processing steps The planning of external services using service master records enables you to assign all the important details, such as the standard description, unit of measure, and price to the external operation using a service number without having to enter it manually.

3-1

Maintenance Order with Service Items Enter an order (order type PM01) for your clarification plant ## in which pipes are to be laid. Create an operation for this order. The task should be performed by an external company. The work should be described using service items. Which control key must you use? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ The entry screen for service specifications appears.

3-1-1 Manual Service Item Create at least one service item manually, that is, without reference to a service master record (for example, cost plus work hours for a pump fitter). Which data must you enter for this? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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3-1-2 Service item with service master record Create at least one service item by selecting an item using the keyword "Pipe" from the general service masters. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Which service master records have you selected? Service number

Description

Quantity/Unit

Price

Which planned total value is displayed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 3-1-3 General purchasing data Go to the general external data screen. Enter the following data if this has not been pre-defined using the relevant Customizing setting: Cost element:

417000

Material group:

007

Purchasing group:

008

Vendor:

1000

Purchasing organization:

1000

Save your order. Which order number is assigned? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 3-2

Purchase Requisition Display your maintenance order again and determine which purchase requisition number has been generated.

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Which menu path do you use? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ What is the purchase requisition number? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Double-click on the purchase requisition and determine the following data: Delivery date Desired vendor Fixed vendor Account assignment category Request date Release date

Check whether or not the services you requested have been transferred to the purchase requisitions. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

3-3

Additional Steps After the order has been created, what are the additional steps in processing for external services based on service items? (Note them down. As a further exercise, you can also execute the steps in the system.) ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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7.32External services as individual purchase order: Solutions Unit: External services Topic: External Services as Individual Purchase Order

1-1

Maintenance Order with External Service SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Create (General) “Operations” tab page; control key: PM02 External processing screen: Field name or data type

Values

Operation quantity

1 PU

Price

5000 per unit 1

Cost element

417000

Material group

007

Purchasing group

008

Vendor

1000 (optional)

Purchasing organization:

1000

Put order in process immediately, if necessary. Order number: 9020xx

1-2

Purchase Requisition SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change “Operations” tab page, double click on operation number >> Actual data tab page on detail screen Purchase requisition number: 1000xxxx

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Purchase requisition details:

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Delivery date

Required end date of operation

Desired vendor

1000

Fixed vendor

1000

Account assignment category

F

Request date

Creation date of operation

Goods receipt

Yes

Invoice receipt

Yes

Release date

Creation date of operation

Additional Steps -

The purchase requisition is converted to a purchase order in Purchasing.

-

A goods receipt is made for the purchase order. This is then updated to the order.

-

An invoice receipt is made for the purchase order. If there are discrepancies between the goods and invoice receipts, these are credited or debited to the order.

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External services with external work centers: Unit: External services Topic: External services with external work centers

2-1

External work centers SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Environment  Work Centers  Work Center  Display Work center: Description

External company group xx

Person responsible

100

Standard value key

SAP0

Control key

PM01

Cost center

4350

Activity type

1610

Formula key

SAP008

Purchase order number (*)

4500004891

Note: The purchase order number is stored as a characteristic in the classification of the work center.

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2-2

Configuring a Maintenance Order Enter T-ME## in the order header as the main work center. Enter T-EX## in the operations as the performing work center. Order number: 9020xx

2-3

Further processing of the maintenance order Obligatory: -

Confirm the order (time)

-

Technically complete the order

-

Settle the order

Optional:

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Plan material

-

Specify estimated costs

-

Assign order budget

-

Check availability

-

Plan capacity

-

Print the order

-

Withdraw planned material

-

Withdraw unplanned material

-

Enter the technical completion confirmation as an activity report

-

Settle the order

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External services with service items Unit: External services Topic: External services as service items

3-1

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Create (General) Field name or data type

Values

Order type

PM01

Functional location

##

Control key in operation

PM03

3-1-1 Manual Service Item In the operation list for the order, double-click on the operation number; the service specifications can be displayed on the detail screen underneath the external data using a tab page. Field name or data type

Values

Service number field

Do not complete

Short text

For example, diggings

Quantity

For example, 15

Unit of measure

For example, m³ (= cubic meters)

Price

For example, $ 85 ( per cubic meter)

3-1-2 Service item with service master record Place the cursor on the Service number field and select individual service items using the matchcode “Service short text” and entering pipe* from the list of service masters. Service master records, for example:

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Service number

Description

Quantity/U Price nit

100029

PipeCut./GasWeld./SegtPipe Sectn w. ZMAK

10 piece

110,00

100005

Transportation of asbestos cement pipe

3 piece

179

Which planned total value is displayed? For example, 2869,00 3-1-3 General purchasing data In the operation list for the order, double click on the operation number; make entries on the external data screen (External tab page is activated automatically by double-clicking on the operation number). Order number: 9020xx 3-2

Purchase Requisition In the operation list for the order, double-click on the operations number; tab Actual data Purchase requisition number: 1000xxxx Check the purchase requisition: Double-click on the purchase requisition number; confirm screen 'Service details' with ENTER, select item and using button 'Item detail' (puzzle symbol), enter it in the item detail screen: Delivery date

Required end date of operation

Desired vendor

1000

Fixed vendor

1000

Account assignment category F Request date

Creation date of operation

Release date

Creation date of operation

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Double-click on the purchase requisition number; confirm screen 'Service details' with ENTER, select item and using button 'Items' (hammer and screwdriver symbol), branch to the service specifications screen.

3-3

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Additional Steps -

The purchase requisition is converted to a purchase order in Purchasing.

-

A service entry is made for the purchase order using a service entry sheet (it is also possible to have several service entries using several service entry sheets for a purchase order)

-

The service entry sheet is released (if a release strategy has been defined in MM Customizing) The release is triggered by entering release codes corresponding to the release strategy.

-

The service entry sheet is accepted

-

Acceptance enables the actual costs to be posted to the order

-

Finally, the invoice is received. Differences between purchase value and invoice value are credited or debited to the order.

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8 Work Clearance Management (WCM)

Contents:  Architecture  Process flow and concept



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8.2 Work Clearance Management: Unit Objectives

At the end of this unit, you will be able to:  Explain the Work Clearance Management concept  Describe how WCM is integrated with Plant Maintenance  Explain the basic WCM architecture



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8.3 Course Overview Diagram

Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical Objects

Refurbishment

Breakdown Maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook



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8.4 Work Clearance Management: Business Scenario

 At IDES, a well defined process must be used to ensure work safety before any maintenance measures are carried out.  This process must be easily understandable and available at all times to employees involved in the maintenance process.  Work Clearance Management makes this possible



SAP AG 2001

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8.5 Need for WCM

 Maintenance crews are working in a hazardous environment (for example, high voltage, radiation exposure)  Maintenance measures need to be performed while systems are operational  Operation of a technical system must not be affected under any circumstances  There are work-related illnesses, which require special health and safety measures



SAP AG 2001

Inspections, repairs, or maintenance work for a technical object may only be carried out when measures to ensure work safety have been implemented. These safety measures include, for example, lockout/tagout, fire protection, radiation protection.  Work Clearance Management (PM-WCM) enables you to control and monitor these activities. This means you are able to ensure safe and secure working conditions for maintenance employees, observe environmental regulations, and guarantee technical system availability. 

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8.6 WCM and the Maintenance Process

Work WorkClearance Clearance Management Management

Maintenance Maintenanceplan plan

Notification Notification

SCADA SCADA



 

Create Create order order

Plan Plan order order

Release Release order order

Work WorkClearance Clearance Management Management

Confirm Confirm order order

Complete Complete order order

History/analysis History/analysis

SAP AG 2001

Orders are linked to WCM at order header level. Connecting orders to WCM is not absolutely necessary. Work clearance management enables you to carry out safety measures without an order.

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8.7 Architecture

Order Work approval Work clearance application

Order

Further applications

Operational WCD

Operational WCD

Enhanced model



 









Work clearance application

Standard model

SAP AG 2001

You can choose between the standard and enhanced model to represent your WCM architecture. The standard model includes the following WCM objects:  Work Clearance Application  Operational WCD The work clearance application represents the safety certificate for lockout/tagout. In the standard model, you use a work clearance application to control communication between orders and Operational WCDs. Direct assignment to orders enables the work clearance application to control the status "Released for execution" in the order. The enhanced model includes the following additional WCM objects:  Work approval  Further applications Work approval is only used in the enhanced model, and represents the central safety certificate. On the one hand, work approvals are assigned to orders where they control the status "Released for execution". On the other hand, work approvals are assigned to applications that they control and check. The decision which model to use is made at individual company level for each planning plant.

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8.8 Work Clearance Document



SAP AG 2001

Enter all technical objects in the WCD that are to be processed using lockout/tagout. The WCD may include equipment, functional locations, technical objects, and commentaries that are not managed in the R/3 structure.  The WCD includes a detailed description of how the system should be isolated.  The WCD controls the physical isolation and placing of tags on the affected technical objects. 

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8.9 Phases and Roles Standard Model (1) Phase/object

1

Order

2

Roles

Create order

Maintenance planner

Work clearance application

Plan order Request tagout/lockout

Maintenance planner

3

Work clearance document

Specify objects containing tagout/lockout details

Work clearance planner

4

Work clearance application

Approve tagout/lockout

Work clearance planner

5

Work clearance document

Perform tagout/lockout

Work clearance planner





Contents

SAP AG 2001

Example: A leakage in a feed-water pump at the biological purification pumping plant must be dealt with. The pump must be opened. The following steps may arise for a maintenance order containing a work clearance management element: 1. A maintenance planner creates the maintenance order. 2. By creating a work clearance application for the order, the maintenance planner requests tagout/lockout for the pump (isolation of the pump so that work can be carried out safely). 3. In the work clearance document, the work clearance planner (safety engineer) records valves 1 and 2 (located in the pipe in front of and behind the pump) as having the tagging condition closed . 4. The work clearance planner (safety engineer) approves the tagging. 5. The tagging is carried out on location: Valves 1 and 2 are closed and are given tags.

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8.10 Phases and Roles: Standard Model (2) Phase/object

Contents

Roles

6

Order

Release order

Maintenance planner

7

Order

Confirm that work in the order is complete

Maintenance planner

8

Work clearance application

Complete tagging

Work clearance planner

9

Work clearance document

Perform untagging

Work clearance planner

10

Order

Technically complete the order

Maintenance planner



SAP AG 2001



6. When tagging has been performed, the maintenance planner can release the order (from a safety perspective). Business order release takes place independently of this. 7. After the work has been carried out and tagout/lockout is no longer required, the maintenance planner sets the status Work complete for the order. Technical completion is independent of this. 8. The work clearance application is completed and untagging approved. 9. Untagging is carried out on location: valves 1 and 2 are re-opened and the tags are removed. 10. The maintenance planner technically completes the order.

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8.11 Standard Model: Example Order Order 1001 1001

Order Order 1002 1002

Order Order 1003 1003

WCA WCA 3001 3001

Operational Operational WCD WCD 4001 4001





Operational Operational WCD WCD 4002 4002

Order Order 1004 1004

WCA WCA 3002 3002

Operational Operational WCD WCD 4003 4003

Operational Operational WCD WCD 4004 4004

Operational Operational WCD WCD 4005 4005

SAP AG 2001

The standard model is useful if the main goal is to support lockout/tagout in the system, and other safety measures play a less important role.

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8.12 Work Clearance Management: Summary

You are now able to:  Explain the Work Clearance Management concept  Describe how WCM is integrated with Plant Maintenance  Explain the basic WCM architecture



SAP AG 2001

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9 Preventive Maintenance

Contents:  Basics  Task list  Single cycle plan  Strategy plan  Maintenance plan scheduling



SAP AG 1999

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9.2 Preventive Maintenance: Unit Objectives

At the conclusion of this unit, you will be able to:  Describe the structure of preventive maintenance in

the PM system  Create and maintain a single cycle plan for simple

preventive maintenance and inspection tasks  Create and maintain a strategy plan for repetitive

maintenance and inspection tasks  Generate orders from maintenance plans



SAP AG 1999

(C) SAP AG

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9.3 Course Overview Diagram

Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook



SAP AG 2001

(C) SAP AG

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9.4 Preventive Maintenance: Business Scenario

 To keep downtimes and maintenance costs to a minimum, the technical systems at IDES are inspected and maintained regularly.  This preventive maintenance is performed based on time, performance, or the condition of the technical object.



SAP AG 1999

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9.5 Preventive Maintenance: Basics

 Basics  Task list  Single cycle plan  Strategy plan  Maintenance plan scheduling



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9.6 Types of Preventive Maintenance

Preventive maintenance

Time-based

Performance-based

Condition-based

2000 30 40 50 60 20 10 70 80

Pressure

Temperature

Pressure

Thickness



SAP AG 1999

Preventive maintenance is divided into three areas: Time-based: Preventive maintenance work is due at specific intervals (for example, every six months).  Performance-based: Preventive maintenance work is due when a specific performance level has been reached (for example, every 10,000 km).  Condition-based: Preventive maintenance work is due when a condition is outside of a specific value range (for example, thread depth below 15 mm or temperature higher than 85° C).  

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9.7 Preventive Maintenance: Phases and Roles Phase

1

Task list

2

Maintenance plan

3

Contents

Roles

Create task lists for different objects

Maintenance planner

Create maintenance plans

Maintenance planner

Schedule

Schedule maintenance plans

Maintenance planner

4

Maintenance order

Process maintenance orders

Maintenance technician

5

Technical completion

Technically complete maintenance orders

Maintenance supervisor



SAP AG 2001

The following types of maintenance plan are available: Strategy-based maintenance plans The maintenance strategy defines the number of packages and their frequency.  Multiple counter plans The counter/time assigned defines when the next call date is due.  Single cycle plan You can also define a maintenance cycle directly in the maintenance plan. This maintenance plan corresponds to a strategy-based maintenance plan with exactly one time-based or counter-based package. In this case, you do not need to create a strategy or assign operations in the task list to this specific package. The total work contained in the specified task list is called up.  

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9.8 Preventive Maintenance: Task List

 Basics  Task list  Single cycle plan  Strategy plan  Maintenance plan scheduling



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9.9 Task List

Operations Maintenance work centers Material components Production resources/tools Maintenance packages For Forpreventive preventivemaintenance maintenance (maintenance (maintenanceand andinspection) inspection) For Forroutine routinemaintenance maintenance (planned (plannedrepairs) repairs) 

SAP AG 1999

Maintenance task lists describe a series of individual maintenance activities. You can use them to standardize recurring activities, plan them more effectively, and save time when creating maintenance orders and maintenance plans.  In the Plant Maintenance system, maintenance task lists can be used for routine and preventive maintenance work. Task lists also specify which spare parts and tools are required for operations and the time needed to perform the work.  If you have created maintenance task lists, you can create maintenance orders and maintenance plans very easily, since you refer to the operations and processes already entered in the maintenance task list. This means that if you create a maintenance order for a task, for which all the individual operations have already been described in a maintenance task list, you only need to specify this task list and the required times in the maintenance order. You do not need not to enter the individual operations because they are copied from the maintenance task list. If the same task is required again shortly afterwards, you can again create the maintenance order with reference to the maintenance task list. 

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9.10 Maintenance Task Lists: Structure

Task list header

Planner group Maintenance strategy

Operation 10 Operation 20 Operation 30

Work center

Components Production resources/tools



SAP AG 1999

The following assignments are made in the task list header:  Planner group, maintenance strategy, and a series of other parameters  The following assignments are possible for operations:  Time, components, work center, and a series of other parameters 

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9.11 Preventive Maintenance: Single Cycle Plan

 Basics  Task list  Single cycle plan  Strategy plan  Maintenance plan scheduling



SAP AG 1999

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9.12 Single Cycle Plan: Business Process

1999

94

96 98

1997 2000

I must perform the same inspections at regular intervals.



 

Inspection of "Portable fire extinguishers"

SAP AG 1999

Business process: The same activity must be executed at regular intervals. Examples:  Annual inspection of fire extinguishers  Acceptance test every two years  Inspection of boilers every six years, as per industry or agency pressure vessel regulations.

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9.13 Scheduling Data and Maintenance Item Interval (cycle)

3 months

Maintenance plan

Scheduling data

Maintenance item

Maintenance item

Reference object Responsibilities/ Planning data 

Task list (optional)

SAP AG 2001

The maintenance item contains the following data:  Planning data (for example, maintenance planning plant, maintenance planner group, order type and so on)  Reference object  Task list (optional)  The scheduling data contains the following:  Cycle/ maintenance intervals  Scheduling parameters for fine-tuning scheduling  List of planned dates and call dates  A maintenance plan can contain one or more maintenance items (for example, maintenance of a pump - a maintenance item for the pump gears with accompanying task list, and a maintenance item for the pump motor with accompanying task list). 

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9.14 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 2001

A task list is assigned within the maintenance item. The operations are executed at the times calculated by the system when scheduling the maintenance plan.  In the case of a single cycle plan, the complete task list is always due.  

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9.15 Preventive Maintenance: Strategy Plan

 Basics  Task list  Single cycle plan  Strategy plan  Maintenance plan scheduling



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9.16 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

Business process: Maintenance work and inspections are performed in different cycles. Example: Service record for a fleet object (excerpt)  Check fan belt: every 12 months  Change fan belt: every 24 months  Change oil: every 6 months  Change oil filter: every 12 months  Check air filter: every 12 months  Change air filter: every 24 months

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9.17 Maintenance Strategy

1997

Scheduling indicator

Package definition

Time - factory calendar

3 months

6 months

9 months

Strategy 

SAP AG 1999

The maintenance strategy consists of several maintenance packages and represents the scheduling rule for preventive maintenance. You can assign task lists to maintenance strategies.  The scheduling indicator determines the scheduling type.  Examples: - Time-based - Time-based using key date - Time-based according to factory calendar - Performance-based  You can assign maintenance packages to a maintenance strategy. The packages for a strategy can have different cycle units (for example, month, year), but they must always have the same dimension (for example, time). 

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9.18 Maintenance Package

Package number Description Cycle length Unit of measurement

Preliminary / follow-up buffer



Offset

Hierarchy

SAP AG 1999

Maintenance packages define the frequency at which specific operations are executed. You can assign maintenance packages to the operations in a task list.  Maintenance packages are part of a maintenance strategy.  Important parameters for a maintenance package are:  Package number  Description  Cycle length  Unit of measurement  Hierarchy If two packages are due on the same date, the hierarchy determines which package is performed.  Offset The offset determines the first due date for a package.  Preliminary / follow-up buffer The preliminary or follow-up buffer specifies the tolerance over which the intended start and end dates for a package can range. 

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9.19 Task List and Maintenance Strategy

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

Task lists can be created for use in preventive maintenance. To prepare task lists for use in strategy plans, the following steps are required:  A strategy is defined in the task list header.  Packages can then be assigned to different operations in the task list. This defines the frequency with which the operations should be executed. 

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9.20 Creating a Time-Based Strategy Plan

Task list

Maintenance plan

Scheduling data

Maintenance item

0010

Switch off

0020

Safety check

0030

External visual check

0040

Change seal

0050

Exchange H9 casing

0060

Check Z7 wire

Strategy



 

SAP AG 1999

You assign a maintenance strategy to a strategy-based maintenance plan. Only a task list, which has the same maintenance strategy as the maintenance plan, can be assigned to a strategy-based maintenance plan.

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9.21 Preventive Maintenance: Maintenance Plan Scheduling

 Basics  Task list  Single cycle plan  Strategy plan  Maintenance plan scheduling



SAP AG 1999

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9.22 Schedule Maintenance Plans

Last actual date Last maintenance package

New start

Cycle start

Start in current cycle *

Manual call Schedule

* Only for strategy plan 



 





SAP AG 2001

Scheduling allows you to define start dates for maintenance orders and always keep them updated. Without regular scheduling, call objects (maintenance orders, notifications, service entry sheets) cannot be created. Scheduling is normally performed automatically and at regular intervals (for example, daily, once a week) in a background job. New start: Function normally used to start a maintenance plan for an object, which has just been put into operation, or for which preventive maintenance work is required. Schedule: Function used to call up the next maintenance order after the last maintenance order has been completed. It is not usually performed manually, but triggered by the technical completion of the order and the deadline monitoring program. Start in current cycle: You can restart scheduling for your strategy plan in the current cycle. This function is useful if you have previously been using a different EDP-system to SAP, or no EDPsystem at all, to manage your maintenance work. For example, if the maintenance strategy, which you have assigned to your maintenance plan, has three packages - monthly, every four months, and every six months, then instead of starting scheduling with the package "monthly", you can decide to start with the six-monthly package and enter the date when the last preventive maintenance work was executed. Manual call: If you also want to schedule a maintenance call for a particular date, you can schedule this date manually.

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9.23 Cycle Start and Planned Date

1 Order 901760

Maintenance plan

Order exactly on planned date?

Scheduling data Planned date Maintenance item

Cycle start 

Cycle 3 months

SAP AG 2001

When you create a single cycle plan, the cycle is assigned, that is, the period until each planned date. Orders are generated based on the planned date. However, the actual call date - the time when the order (or notification / service entry sheet) is, in fact, generated - can differ from the planned date.  The cycle start defines the date from which the calculation of the planned dates should begin. 

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9.24 Maintenance Scheduling Overview

Maintenance item report, sorted by equipment (no.)

... as a graphic With maintenance plan simulation With/without details 1999

1998

... or as a list With display variants With general list viewer



SAP AG 1999

You can use the scheduling list to display all the maintenance dates for the conditions you have defined, for example, for a piece of equipment, or for a maintenance plan.  The scheduling list provides information about call dates and associated maintenance orders.  You can also call up detail screens from this list. 

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9.25 Preventive Maintenance: Summary

You are now able to:  Describe the structure of preventive maintenance in the

PM system  Create and maintain a single cycle plan for simple

preventive maintenance and inspection tasks  Create and maintain a strategy plan for repetitive

maintenance and inspection tasks  Generate orders from maintenance plans



SAP AG 2001

(C) SAP AG

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9.26Task

list: Exercises Unit: Preventive maintenance Topic: Task list

At the conclusion of these exercises, you will be able to:  Display task list details

You can use task lists to store the recurring sequence of operations as a master record. These operations can then be included either in a maintenance plan or in order planning.

1-1

What are task list groups and group counters used for? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

1-2

Display the task list header of the general maintenance task list PUMP_WTG with group counter 1. How do you proceed? Which parameters indicate that this task list has been defined for strategy-based maintenance planning? What is the value? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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1-3

Display the operation list. How do you proceed? Which maintenance packages have been assigned to which operations? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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Single Cycle Plan: Exercises Unit: Preventive maintenance Topic: Single cycle plan

At the conclusion of these exercises, you will be able to:  Configure a single cycle plan  Use a pre-defined task list

You can use a single cycle plan to display similar tasks that are due at the same intervals.

2-1

Creating a Single Cycle Plan A mechanical inspection should be performed every three months for your piece of equipment TEQ-##. When this inspection takes place, all the operations in task list PUMP_REP with group counter 2 should be executed.

2-1-1 Which menu path do you use? Use the maintenance plan category Plant Maintenance. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

2-1-2 After you have entered your equipment number, the system displays various default values. Which default values are shown? Where do they come from? Value

Source

Maintenance planning plant Maintenance planner group Order type Maintenance activity type (C) SAP AG

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Main work center Business area

2-2-1 Task list What options do you have for defining operations in the maintenance plan? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

2-2-2 Include the task list in your maintenance plan. How do you proceed? ____________________________________________________________ ____________________________________________________________ When you save the maintenance plan, the current date is proposed as the start date. Confirm this start date and copy it to the maintenance plan.

Save your maintenance plan. Which number is assigned to it? ____________________________________________________________

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Strategy Plan: Exercises Unit: Preventive maintenance Topic: Strategy Plan

At the conclusion of these exercises, you will be able to:  Display a maintenance strategy  Configure a strategy plan  Use a pre-defined task list with determination of maintenance packages If different tasks are due according to different cycles, this can be represented using a strategy-based maintenance plan.

3-1

Displaying a Maintenance Strategy Display the maintenance strategy A and determine the following data: Maintenance strategy header Scheduling indicator Strategy unit Late completion confirmation SF Early completion confirmation SF Maintenance packages

(C) SAP AG

Short text

Cycle length Unit

LO100

Hierarchy

30

3-2

Creating a Strategy Plan Preventive electrical maintenance tasks are to be performed at your piece of equipment TEQ-##. However, the tasks have different cycles.

3-2-1 Enter a strategy plan with maintenance plan category Plant Maintenance for maintenance strategy A for your piece of equipment TEQ-##. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

3-2-2 Include the general maintenance task list PUMP_WTG with group counter 2 in the strategy plan. Which maintenance packages are used? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 3-2-3 Determine the maintenance cycles in which the individual operations are due. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Operation

Maintenance package(s)

Save your maintenance plan. Which number is assigned to it? ____________________________________________________________

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Maintenance Plan Scheduling: Exercises Unit: Preventive maintenance Topic: Maintenance Plan Scheduling

At the conclusion of these exercises, you will be able to:  Restart a maintenance plan  Start a maintenance plan in the cycle  Display the scheduling overview  Display your maintenance orders Using maintenance plan scheduling, maintenance dates due regularly in the maintenance plans are converted into maintenance orders, and dates that are on hold are recalculated if the scheduling parameters are changed.

4-1

Restarting a Single Cycle Plan Start your single cycle plan for the 1st of the current month. Which is the first due date? ____________________________________________________________ Save the maintenance plan.

4-2

Starting a Strategy Plan in the Current Cycle Start your strategy plan so that the first 3-month-package was performed on the 28th of the previous month. How should you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Which is the next due date? Which package is due then? ____________________________________________________________ Save the maintenance plan.

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4-3

Displaying Maintenance Orders How do find the maintenance orders you have generated? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Which order numbers have been generated? ____________________________________________________________

4-4

Scheduling Overview Display an overview of the due maintenance dates in list form for your maintenance plans. Which menu path do you use? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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9.27Task list: Solutions Unit: Preventive maintenance Topic: Task list

1-1

The task list group combines task lists with similar topics from logical and datarelated perspectives. The group counter is the sequence number of a task list within the task list group.

1-2

Display the task list header: SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Task Lists  Task Lists  General Maintenance Task Lists  Display Task list grp:

PUMP_WTG

Task list group counter: 1 “Header” button The value A is entered in the “Maintenance strategy” field (calendar-based scheduling). This shows that the general task list should be used for time-based strategic maintenance. Strategy A provides the maintenance packages (cycles) which are available for the operations. 1-3

Display the operation list: From the task list header, button “Operation”; then button “MntP” to display the maintenance packages for all operations.

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Single Cycle Plan:

Unit: Preventive maintenance Topic: Single cycle plan

2-1-1 Creating a Single Cycle Plan SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Maintenance Plans  Create  Single Cycle Plan Field name or data type

Values

Maintenance plan number

Do not specify (internal number assignment)

Maintenance plan category

Plant Maintenance

Short text / description

Enter as required

Cycle

3 MON

Equipment

TEQ-##

2-1-2 Default values: Field

Value

Source

Maintenance planning plant

1000

Equipment

Maintenance planner group

I##

Equipment

Order type

PM02

Customizing

Maintenance activity type

102

Customizing

Main work center

T-ME##

Equipment

Business area

1000

Equipment

2-2-1 Task list (C) SAP AG

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1. Button 'Select task list' (binoculars) and set a selection condition 2. Use button 'Create task list' (white sheet of paper) to create a new general task list 3. Do not specify a task list; a standard operation (short order) is then generated in the subsequent maintenance order using the short text from the maintenance item.

2-2-2 Including a Task List: - Binoculars button (select task list) - Activate task list category for General task list - For example, enter Pump* as a selection criterion in the ‘Task list group’ field - Make a selection and choose the required general task list from the following list (task list type A, task list group PUMP_REP, task list group counter 2) Save your maintenance plan. Which number is assigned to it? For example, 60

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Strategy Plan: Unit: Preventive maintenance Topic: Strategy Plan

3-1

Maintenance strategy SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Maintenance Strategies Display Maintenance strategy header Field name or data type

Values

Scheduling indicator

Time

Strategy unit

MON

Late completion confirmation SF

100%

Early completion confirmation SF

100%

Maintenance packages

Short text

Cycle length

Unit

Hierarchy

1

1M

1

MON

1

2

3M

3

MON

1

3

1Y

12

MON

2

3-2-1 Creating a Strategy Plan SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Maintenance Plans  Create Strategy Plan

(C) SAP AG

Field name or data type

Values

Maintenance plan number

Do not specify (internal number assignment)

Maintenance plan category

Plant Maintenance

Maintenance strategy

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Short text / description

Enter as required

Equipment

TEQ-##

3-2-2 Including a General Task List: - Binoculars button (select general task list) - the strategy (as a selection parameter) is also used automatically (here, A). In other words, only task lists with this maintenance strategy are selected. - Make selection as in section 2-2-2 - Maintenance packages used: 1M, 3M and 1Y

3-2-3 Maintenance packages in task list: Button 'Display task list' In the operation overview, button 'MntP' (you do not need to select the operations).

(C) SAP AG

Operation

Maintenance package(s)

0010

1M, 1Y

0020

1M, 1Y

0030

1M, 1Y

0040

1M, 1Y

0050

3M, 1Y

0060

1M, 3M

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Maintenance Plan Scheduling Unit: Preventive maintenance Topic: Maintenance Plan Scheduling

4-1

Restarting a Single Cycle Plan SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Scheduling for Maintenance Plans  Schedule Edit  Start If a start date was transferred to the maintenance plan when the strategy plan was created, this is now proposed. If no start date has yet been entered in the maintenance plan, one must now be set (for example, current date). The start and ongoing scheduling of all maintenance plans is not usually executed manually, but using deadline monitoring which is controlled by a system job.

4-2

Starting a Strategy Plan in the Current Cycle SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Scheduling for Maintenance Plans  Schedule

(C) SAP AG

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Button ‘Start in cycle’

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Confirmation date, for example, 28th of the previous month, then button ‘Select package’

-

Cursor on first package '3M', button ‘Start offset’ and back

-

The next due planned date is displayed in the list of scheduled calls according to the entry

-

Packages due: 1M

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4-3

Displaying Maintenance Orders 1. Using list editing for orders: SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  List of Orders  Change Order type PM02 2. Maintenance plan scheduling: SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Scheduling for Maintenance Plans  Schedule - ‘Scheduled calls’ tab page - Select a line with the status ‘Called’ - Symbol ‘Display orders’ (glasses) 3. Displaying/Changing a Maintenance Plan SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Maintenance Plans  Display/Change - ‘Scheduled calls’ tab page - Select a line with the status ‘Called’ - Symbol ‘Display orders’ (glasses) Order numbers: 9020xx

4-4

Scheduling Overview SAP menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Scheduling for Maintenance Plans  Scheduling Overview  List - Enter maintenance plan numbers - Execute Additional fields can be shown analogous to the notification and order lists using Settings  Display variants  Current.

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10 Refurbishment

Contents  Material master  Refurbishment order

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10.2 Refurbishment: Material Master

 Material master  Refurbishment order

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SAP AG 2001

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10.3 Refurbishment: Unit Objectives

At the conclusion of this unit, you will be able to:  Define the condition of materials  Assign values to materials based on their condition  Serialize equipment  Create a refurbishment order  Post inward and outward stock movements of

materials based on their condition  Explain the change in material price and stock value

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10.4 Course Overview Diagram

Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook

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10.5 Refurbishment: Business Scenario

 At IDES, faulty equipment must first be dismantled and returned to the warehouse, where it can later be refurbished.  For this purpose, a material with condition-based value, which is linked to the equipment, is used to monitor availability of stock in inventory management.

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SAP AG 1999

The refurbishment process described here is a stock-based refurbishment. The parts to be processed belong to the current assets.  The value of these parts should also be represented correctly in stock after their dismantling and/or refurbishment.  For machines and technical systems, which form part of the fixed assets, this process does not serve any purpose since the condition (fit for use / unfit for use) is not important for the valuation of a technical system. 

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10.6 Refurbishment Phases and Roles Phase

Contents

Initiate Refurbishment

Defective material in stock with condition-based value

Maintenance engineer

Order

Create refurbishment order

Maintenance planner

3

Material withdrawal

Remove defective material

Maintenance technician

4

Refurbishment

Carry out refurbishment

Maintenance technician

5

Return

Return refurbished material to storage

Senior storeperson

1 2



  

 

 



Roles

SAP AG 2001

Equipment dismantling: The faulty equipment is first dismantled. Placement in storage: The equipment is posted to stock using the material number, which has been assigned to it using serialization. Creation of refurbishment order: As soon as the number of defective repairable spares in the warehouse has reached a certain level, the maintenance planner responsible creates a refurbishment order. The planner defines the time allowed for the refurbishment and plans all the operations, materials, tools, and so on required for the refurbishment. Order release: After planning has been completed, the refurbishment order is released. Withdrawal from warehouse: The employees responsible withdraw the defective/used repairable spares and any other materials planned in the order, which are required for the refurbishment, from the warehouse. Completion confirmation: The employees responsible for refurbishment confirm the work done for the refurbishment order. These completion confirmations indicate how the work is progressing. Return to warehouse: The repaired/refurbished repairable spares are returned to the warehouse per goods receipt in accordance with the order planning. You can call up the object list from the refurbishment order to help identify individual repairable spares. If repairable spares cannot be refurbished, the reservation is canceled and the items are posted for scrap. Order completion: As soon as refurbishment is finished, the order can be completed.

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10.7 Valuation Category and Valuation Type

Valuation categories

Valuation types

R=Reference

I Internal

C=Condition

C1 New part E External

O=Origin

....

D Domestic

C2 Refurbished

A Abroad

C3 Defective

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SAP AG 1999

In the material master record, a price is defined for the material for each valuation area (= plant or company code). However, in some cases, you need several prices for the same material within one valuation area (separate material valuation): You want to value stocks of a material individually depending on the condition (new/used/defective).  If a material is to be valued separately, it must be identified as such. This identification is made in the material master record by defining a valuation category (for example, C for condition-based valuation) in the accounting data. The valuation category is a key that specifies the criterion by which the partial stocks should be distinguished.  Each material to be valued separately is clearly assigned to a valuation category in the material master record. Based on this valuation category, the material can now be assigned to the relevant valuation types.  If the material is valued separately, each partial stock of this material must be assigned to a valuation type (for example, new, refurbished, defective). The user assigns the valuation type (external number assignment, here: C1, C2, C3). 

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10.8 Valuation Category and Type in Material Master

Change material: Accounting 1

Valuation category

Valuation type



Valuation category

C

Price control Moving average price

V 1,245.67

Change material: Accounting 1 Valuation type C1 Valuation category

C

Price control Standard price

S 3,200

Automatically calculated

SAP AG 1999

Two types of data are available for a valuation type:  Valuation data (for example, valuation price, total stock, total stock value) which is defined for each valuation type in the valuation area and applies to all associated storage locations.  Stock data which is managed per storage location like batch data. If the material valued separately is to be handled in batches, the stock data is not managed per valuation type but per batch. Each batch is assigned to a valuation type.  The stock quantity, stock value and valuation price for all the valuation types are accumulated at valuation area level. The result is the moving average price for the material. 

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10.9 Condition-Based Material Valuation

Material Material

withvaluation valuationcategory categoryCC with (condition-based (condition-based valuation) valuation)

Valuationtype type Valuation Valuationtype type Valuation Valuationtype type Valuation C1 C2 C3 C1 C2 C3 $ 3,000 $ 2,500 $ 200 $ 3,000 $ 2,500 $ 200

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SAP AG 1999

If a material is valued separately, this material is managed in various partial stocks, and each partial stock is valued separately.  Every operation subject to valuation - whether it is a goods receipt, goods issue or inventory - is performed at partial-stock level. When you process one of these operations, you must always specify which partial stock is involved. This ensures that only the value of the partial stock concerned can be changed; the other partial stocks remain unaffected.  In addition to partial stocks, the overall stock is also updated. The value calculated for the overall stock is derived from the total of stock values and stock quantities for the individual partial stocks. 

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10.10 Moving Average Price

Stock C1 C1 C1 C1 C1 10 items at $ 3,000 each

Stock C2 C2 C2 C2 C2 20 items at $ 2,500 each

Stock C3 C3 C3 C3 C3 10 items at $ 200 each

Movingaverage averageprice price Moving $ 2,050 $ 2,050

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SAP AG 1999

The stock quantity, stock value and valuation price for all the valuation types are accumulated at valuation area level. The result is the moving average price for the material.  The stocks for a material valued separately are managed separately for each valuation type. They are combined in the valuation header record. The individual stock quantities and stock values are totaled here. A moving average price is calculated from the values for the individual valuation types and stock quantities. 

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10.11 Refurbishment: Refurbishment Order

 Material master  Refurbishment Order

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10.12 Refurbishment Order

Must be declared as refurbishment order in Customizing

Maintenance order 800175 Order type PM04 Material P-2001 Normal suction pump Serial number 53 (Equipment no. P-1000-n001) Quantity 3 From C3 To C2

Quantity of parts to be refurbished

Actual condition before refurbishment Target condition after refurbishment



SAP AG 1999

The structure of the refurbishment order essentially corresponds to the structure of the maintenance order.  When creating a refurbishment order, you have to enter at least the following data:  Material number to be refurbished  Quantity to be refurbished  Actual condition to be refurbished (for example, C3)  Target condition to be achieved (for example, C2) 

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10.13 Refurbishment Order: Stock Withdrawal

Stock

Maintenance order 800175 Order type PM04 Material P-2001 Normal suction pump Serial number 53 (Equipment no. P-1000-n001) Quantity 3 From C3 To C2



C3

C3 C3

Stock withdrawal with movement type 261

SAP AG 1999

When a refurbishment order is created, the following planned goods movements of parts to be refurbished are generated in the background:  Automatic creation of material to be provided ("from" condition) as order component/reservation  Automatic creation of material to be delivered ("to" condition) as order item/material receipt element  The goods issue of the material to be provided ("from" condition) is made as a planned material withdrawal using movement type 261 with reference to the order number. 

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10.14 Refurbishment Order: Inward Stock Movement

Maintenance order 800175 Order type PM04 Material P-2001 Normal suction pump Serial number 53 (Equipment no. P-1000-n001) Quantity 3 From C3 To C2

Inward stock movement with movement type 101

Stock C2



C2 C2

SAP AG 1999

When a refurbishment order is created, the following quantities of parts to be refurbished are generated in the background:  Automatic creation of material to be provided ("from" condition) as order component/reservation  Automatic creation of material to be delivered ("to" condition) as order item/material receipt element  The refurbishment order is completed by a goods receipt. The goods receipt of the material to be delivered ("from" condition) is made as a planned goods receipt using movement type 101 with reference to the order number. 

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10.15 Effect of Refurbishment on Stock Value of Material Stock value before processing Condition Price Quantity C1 C2 C3

$ 3,000.00 $ 2,500.00 $ 200.00

Stock value Moving average price

10 20 10

Stock value $ 30,000.00 $ 50,000.00 $ 2,000.00 $ 82,000.00 $ 2,050.00

Stock value during processing Quantity 10 21 9

Stock value after settlement

Stock value

Quantity

$ 30,000.00 $ 52,500.00 $ 1,800.00

10 21 9

$ 84,300.00 $ 2,107.50 

Stock value $ 30,000.00 $ 50,812.55 $ 1,800.00 $ 82,612.55 $ 2,065.31

SAP AG 2001

The total stock value of the material increases after settlement by the effective resources required (working time + material, here: five hours to a total of $ 812.55).  As a result, the moving average price is also increased at the level of overall material.  If the partial stocks (batches) are valued at a standard price, the stock value after settlement is the same as during processing, in other words, the effective resources required do not enter the material valuation; the valuation is only oriented to the standard price of the target batch. 

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10.16 Refurbishment: Unit Summary

 Materials are assigned values based on their condition.  Refurbishment orders can be processed with or

without serial numbers.  After refurbishment, the value of stock in the

warehouse and the debit to the cost center both change.

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SAP AG 1999

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10.17The

Material Master: Exercises Unit: Refurbishment Topic: Material Master

At the conclusion of these exercises, you will be able to:  Display the material master  Determine the valuation category and valuation types  Determine stocks and valuations Warehouse-based refurbishment is based on the condition-based valuation of the material, for which the different conditions are represented using internal valuation types. In this way, a verification document concerning the value of the change to the material can be maintained for refurbishment.

1-1-1 A certain quantity of defective pumps with material number T-FP1## has been collected in the warehouse. These should now be refurbished. However, before the refurbishment starts, you want to obtain an overview of certain core data for this material. Call up the accounting data for material master T-FP1## for plant 1000 and determine the following data. Which menu path do you use?

Determine the following data at header level: Description Price control Valuation category Moving average price Standard price Total stock Total value (C) SAP AG

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1-1-2 So that the different conditions (new, refurbished, defective) can be represented, the material has different valuation types. Which valuation types have been defined for the material T-FP1## ? ____________________________________________________________ Determine the following data for each valuation type: Valuation type

Valuation type

Valuation type

Valuation category Price control Moving average price Standard price Total stock Total value

1-1-3 Stock balance display Display an overview of the stock. Which menu path do you use? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ How do you limit the selection? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Determine the following stock values: Unrestricted use

Reserved

Open purchase order quantity

Plant 1000 Storage location 0001 Batch: Batch: Batch:

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Refurbishment Order: Unit: Refurbishment Topic: Refurbishment Order

At the conclusion of these exercises, you will be able to:  Configure and process a refurbishment order  Perform a material withdrawal and material receipt

Refurbishment processing is performed using an order type configured for this purpose. This enables you to perform refurbishment for material and pieces of equipment linked to a material number.

2-1

Create a refurbishment order for material T-FP1## from batch C3, using the following data: Order type

PM04

Maintenance planning plant

1000

Business area

1000

Maintenance planner group

I##

Employee responsible Work center

T-ME##

Total quantity

1 piece

From plant/storage location/valuation type

1000 / 0001 / C3

To plant/storage location/valuation type 1000 / 0001 / C2 Which menu path do you use? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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2-2

Operations Create the operations you regard as necessary to process the order. Use work center T-ME## and control key PM01 each time. ____________________________________________________________ ____________________________________________________________

2-3

Material planning Check the component list for operation 0010. Which entries do you find? Material number Quantity Item category Plant Storage location Batch Plan further spare parts which you regard as necessary for processing the order. Which did you plan? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Put the order in process without printing it. Which order number is assigned? ____________________________________________________________

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2-4

Material withdrawal Withdraw the material planned for your order. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Which document number is assigned? ____________________________________________________________

2-5

Time confirmation Enter the actual times for your order using single entry or collective entry. Set the final confirmation indicator each time. How many hours have you confirmed in total? ____________________________________________________________

2-6

Goods receipt Post the return of the refurbished part to the warehouse for your order. How do you proceed? ____________________________________________________________ ____________________________________________________________ Which document number is assigned? ____________________________________________________________

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Controlling Unit: Refurbishment Topic: Inventory Management and Controlling

At the conclusion of these exercises, you will be able to:  Settle a refurbishment order  Check stocks  Perform a cost analysis for the order The refurbishment order is settled directly to the material. Depending on the price control of the condition batches (valuation types), values are assigned based on the standard price of the valuation type or the actual resources required. The check can also be made using the cost report in the order.

3-1

Cost Analysis of the Order Call up the cost report for the planned/actual comparison and check which credits and debits the order has before settlement. How do you proceed? Cost element debit

Actual costs

Cost element credit

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3-2

Which settlement rule is used for the order? ____________________________________________________________ ____________________________________________________________

3-3

When is the stock value changed for material T-FP1## and why? Are the actual working time and spare parts required considered when the stock value is changed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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10.18The Material Master: Solutions Unit: Refurbishment Topic: Material Master

1-1-1 Display the Material Master SAP menu  Logistics  Plant Maintenance  Technical Objects  Material  Display Data at header level Field name or data type

Values

Description

Normal suction pump SIHI 200-100

Price control

V

Valuation category

C

Moving average price

2.050,00

Standard price

2.456,90

Total stock

40

Total value

82.000,00

1-1-2 Display valuation types SAP menu  Logistics  Plant Maintenance  Technical Objects  Material  Display Enter material number T-FP1## and choose Accounting view; call up F4 Help in the Valuation type field >> The following valuation types appear: C1, C2 and C3

(C) SAP AG

Valuation type C1

Valuation type

Valuation type

C2

C3

Valuation category

C

C

C

Price control

S

S

S

Moving average price

3000,00

2500,00

200,00

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Standard price 3000,00

2500,00

200,00

Total stock

10

20

10

Total value

30000,00

50000,00

2000,00

1-1-3 Stock balance display SAP menu  Logistics  Plant Maintenance  Technical Objects  Material  Display In the material: Environment  Stock overview or SAP menu  Logistics  Plant Maintenance  Technical Objects  Material  Stock Overview Stock values:

(C) SAP AG

Unrestricted use

Reserved

Open purchase order quantity

Plant 1000

40

0

0

Storage location 0001

40

0

0

Batch: C1

10

0

Batch: C2

20

0

Batch: C3

10

0

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Refurbishment Order: Solutions Unit: Refurbishment Topic: Refurbishment Order

2-1 SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Create (Special)  Refurbishment order

(C) SAP AG

Field name or data type

Values

Order type

PM04

Material

T-FP1##

Planning plant

1000

Business area

1000

Maintenance planner group

I##

Employee responsible Work center

T-ME##

Total quantity

1 piece

From plant/storage location/valuation type

1000 / 0001 / C3

To plant/storage location/valuation type

1000 / 0001 / C2

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2-2

Operations In the order, 'Operations' tab page > Enter useful operations for performing refurbishment

2-3

Material planning From the operation list, double-click on operation number 0010 > The system branches to the internal processing screen for the operation which displays the component list in the lower screen area. Component T-FP1## is scheduled automatically with the following data: Field name or data type

Values

Material number

T-FP1##

Quantity

1

Item category

L

Plant

1000

Storage location

0001

Batch

C3

Plan additional materials using free material assignment (execute F4 help in the field Components and search, for example, for a material short text)`; possible materials: 100-100, 100-400, 100-431, 100-600, and others; Choose the Put in process button;

2-4

Material withdrawal SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Goods Movement Field name or data type

Values

Movement type

261

Plant

1000

Storage location

0001

Material

T-FP1##

serial number

For example, 41

Choose button 'To order...' and enter order number; save. 2-5

(C) SAP AG

Time confirmation

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SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Entry  Overall Completion Confirmation or SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Entry  Individual Time Confirmation

2-6

Goods receipt SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Completion Confirmation  Goods Movement  Refurbishment Goods Receipt > Enter order number from 2-3 > In “Activity” area, activate Change batch/valuation type + Posts goods receipt (this is the standard setting) > Control data in “Data for goods receipt” area > Select line with serial numbers > Save

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Inventory Management and Controlling: Unit: Refurbishment Topic: Inventory Management and Controlling

3-1 SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change Extras  Cost reports  Planned/actual comparison Cost element debit

Actual costs

404000 Spare parts

For example, 200

615000 Direct activity allocation

For example, 129, 53

655901 Overhead rates

None, since these cannot be calculated automatically

Cost element credit 895000 Factory production

For example, 2,500

The service provided by the refurbishment is posted to the order as credit in the form of negative costs. The value results from the values assigned to the C2 batch of material T-FP1## (standard price valuation).

3-2 (C) SAP AG

SAP menu  Logistics  Plant Maintenance  Maintenance Processing  Order  Change LO100

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Goto  Settlement rule MAT

T-FP1##

100% GES

The settlement rule is created automatically. The settlement is made directly to the material.

3-3

Since the material T-FP1## has a standard price valuation at the level of valuation type (= batch), the stock value is changed for the return of the refurbished part to the warehouse (in batch C2). As a result of the standard price valuation, an item received in the C2 batch is always assigned the value 2,500 and thereby leads to an increase in the stock value at overall material level. The actual working time and spare parts required are not considered for the standard price valuation of batches. The resources required can only be considered if a moving average price has been agreed at batch level. The actual resources required are then settled to the material when the order is settled (not when it reaches the warehouse).

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11 Reporting and Analyses

Contents:  Maintenance history  Evaluations and analyses



SAP AG 1999

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11.2 Reporting and Analyses: Unit Objectives

At the conclusion of this unit, you will be able to:  Describe the sections of the maintenance history  Check the usage list for a piece of equipment  Perform standard analyses for specific

characteristics and key figures in Plant Maintenance



SAP AG 1999

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11.3 Course Overview Diagram

Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook



SAP AG 2001

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11.4 Reporting and Analyses: Business Scenario

 Evaluations of technical and cost-oriented details should be object-related or area-based.  Online updating of data guarantees quick, optimized access to the required characteristics and key figures.



SAP AG 1999

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11.5 Reporting and Analyses: Maintenance History

 Maintenance history  Evaluations and analyses



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11.6 Evaluations: Phases and Roles

Phase

1

Master/ Movement data

2

Evaluations



Contents

Roles

Master and movement data are updated online

All

Analyze the relevant key figures

Maintenance manager

SAP AG 2001

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11.7 Usage List S-15

Usage list

03/01/ - 09/20/98



S-15

SAP AG 1999

The usage list provides both object-related and location-based information about equipment usage. 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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11.8 Maintenance History Completed notifications

Completed orders

Object

Damage description

Work center

Objects damaged Downtimes

Scheduling of work

Activities

Material usage

Tasks



Lists

Costs by class

SAP AG 1999

Analyses in maintenance processing are based on completed notifications or orders and historical orders.  Completed notifications and orders You can use completed notifications and orders for medium-term evaluations. A notification is transferred to the notification history when completed, whereas an order is transferred to the section for completed orders. The data for completed notifications and orders can be analyzed in full. 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 longterm analyses. They are transferred to the order history. Historical orders contain the most important order data in condensed form. Evaluations can be performed in the list editing function for the orders, where the status "Historical" must be set. 

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11.9 Material Usage

Example:

Material 100-100

Order

100-100



Use of material 100-100 from 01/01/1997 to 01/01/1998 Notifictn. Fun. loc. Equipment

Work ctr

Reserved ME

Reserv. ref. ME

901021 901021 901118 901234 1000056 901256

1000253 1000255 1000255 1000253 1000255

MECHMNT MECHMNT MECHMNT MECHMNT MECHMNT

2 1 2 1 2

PC PC PC PC PC

2 1 2 1 2

PC PC PC PC PC

904051 1000083

1000258

MECHMNT

18

PC

18

PC

18

PC

18

PC

SAP AG 2001

You can use the "Material where-used list" function to verify the use of materials in maintenance orders within a specific period of time.  Orders can be chosen according to different selection criteria, for example, by order number, order type, equipment and so on.  The material where-used list also indicates which materials were planned withdrawals, for example, with reference to a reservation, and which were unplanned (without reference to a reservation). 

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11.10 Reporting and Analyses: Evaluations and Analyses

 Maintenance history  Evaluations and analyses



SAP AG 1999

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11.11 Data Flow in LIS

Standard analysis Analysis program

Analysis program

S061

S...

Information structure

S062

S061/SAP

S062/XYZ

Location Plan

Class Manufact.

... ...

Update rules

... ...

LIS interface

MCVBAK MCVBAP Work order EQUI Processing 

QM

SAP AG 1999

EQUI

QM

Application

The Logistics Information Systems (LIS) have a modular structure and can be analyzed in a number of different ways.  All information systems have a common user interface and their own databases.  This structure allows individual information systems to retain their special features.  Data stored in the Logistics Information System is "fed" into LIS from the application when transactions are processed.  Information stored in LIS can be displayed in different ways.  Users can determine how much information they want to see. 

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11.12 Organization of Information Structures

Period unit

Characteristics

Key figures

398 157

005

Week Maintenance Functional planning location plant



March March Mo Tu We Th Fr Sa

11 11 Su

Total actual costs

Reported breakdowns

Average Order Delivery quantity. . . repair number time

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The Plant Maintenance Information System (PMIS) is based on information structures. These are special statistical tables that contain basic data from different applications. This data is constantly collected and updated by the system.  Information structures contain three basic types of information:  Characteristics are criteria which you specify to collect information about a particular subject. For example, in Controlling, you normally require information about workshops and materials.  A period unit (periodicity) is also a criterion used in information structures. You can collect data for a particular day, week, month or posting period.  Key figures are measurements of performance which provide important business information about a characteristic.  From a technical perspective, characteristics and period units are key terms that are used to sort data in databases. 

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11.13 Information Structures in Plant Maintenance Examples:

Characteristics

Time

Key figures

From From Sales Sales & & Distribution Distribution Customer

Material

Month

Order quantity

Order value

No. of orders

...

...

From From Plant Plant Maintenance Maintenance Planner group

No. of

Equipment

Maintenance Duration costs

...

No. of Maintenance Order maintenance costs quantity orders

...

Month maintenance orders

Logistics Logistics in in general general Material 

Plant

Month

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The PMIS contains the following standard information structures:  S061 = Location and Planning  S062 = Object Class and Manufacturer  S063 = Damage Analysis  S065 = Object Statistics  S115 = Cost Evaluation  S116 = Sales Notification and Analysis  You can use the relevant standard analyses to evaluate data, without having to make additional settings in Customizing. 

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11.14 Standard Analysis Options

Additional information

Drill-down by planner group

Planning-related analysis Planning plant 1000 90 68,000

ABC analysis Classification

Equipment master record Order

Functions

Planning plant: 1000 Order Planner Order number costs group Drill52 26,000 down by 010 020 38 42,000 period

Dual classification Planned/actual comparison Cumulative frequency curve Correlation

Planning plant: 1000 Planner group: 010 Month Order Order number costs 02.1998 28 14,000 03.1998 24 12,000



 







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Standard analyses provide many functions that enable you to find specific information for detailed evaluations. The information structures provide the database for standard analyses.  You can specify the range of data to be evaluated.  You can define the key figures or choose them online during the analysis itself. The drill-down function allows you to vary the detail of information.  You can specify the sequence in which levels of information are displayed or you can follow the standard drill-down sequence.  Different functions are available at each level, for example, cumulative frequency curves, ABC analyses, correlation, classification, dual classification, and ranking lists.  All the results can also be displayed graphically. You can save the data selected for standard analysis as a selection version.  Selection versions also enable you to define the way you view the data.  You can select data in the background at any time. You can access summary information in the information structure and branch to the display of master data and movement data.

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11.15 Standard Report in CO Order: Planned / actual variance Fiscal year: Period:

1999 1-12

Orders: 901000 - 908000

Cost elements 410000 Use of trading goods 415000 External procurement 417000 Services 615000 Repairs ...



Actual

Planned

Variance

35,000 70,000 100,000 250,000

30,000 60,000 95,000 200,000

5,000 10,000 5,000 50,000

SAP AG 1999

Data that has been accrued and collected in Plant Maintenance (for example, in maintenance orders) can also be analyzed from a cost accounting perspective in Controlling (CO). For example, a CO report on planned/actual variances in orders can be used to analyze maintenance orders.  You can still use line item reports for orders or cost centers for evaluation purposes. 

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11.16 Reporting and Analyses: Unit Summary

You are now able to:  Describe the principle of integrated data  Explain how an information structure is configured  List the different analysis options  Perform standard analyses

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11.17Evaluations

and analyses: Exercises

Unit: Reporting and analysis Topic: Evaluation and analysis

At the conclusion of these exercises, you will be able to: 

List the different parts of the maintenance history



Perform standard analyses

When monitoring activities in Plant Maintenance, it is important for you to be able to perform evaluations and analyses of costs, damage, usage times and so on, quickly and easily.

1-1

What are the components of the maintenance history? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

1-2

Your pump P-1000-N001 often breaks down. You want to check where this pump has been installed to draw possible conclusions about the frequency of damage. How can you display a list of installation locations for P-1000-N001? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

1-3

What are the central modules for evaluations and analyses in the Plant Maintenance Information System? How are these structured? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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1-4

What is a standard analysis? Which standard analyses are available in the Plant Maintenance Information System? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

1-5

Perform a location analysis for the period from 01/01/1998 to the current date for maintenance plant 1000. Which piece of equipment involved the greatest overall costs? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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11.18Evaluations and analyses: Solutions Unit: Reporting and analysis Topic: Evaluation and analysis

1-1

The components of the maintenance history are: - Completed notifications - Completed and historical orders - Usage lists

1-2

SAP menu  Logistics  Plant Maintenance  Technical Objects  Equipment  Change Extras  Usage list > The list of equipment usage periods is displayed Settings  Display variants  Current Activate Functional location field

1-3

The central modules for evaluations and analyses are the Plant Maintenance information structures Information structures form the basis for standard analyses and analyses created by the user. They contain a combination of characteristics (for example, maintenance planning plant, equipment) and key figures (for example, number of orders, total actual costs) with time base. In the standard system, the information structures S061, S062, S063, S065, S115 and S116 are available.

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The following standard analyses are available in the standard system: Field name or data type

Values

Standard analyses

Object class Manufacturer Location Planner group Damage analysis Object statistics Breakdown analysis Cost analysis

1-5 SAP menu  Logistics  Plant Maintenance  Information System  Standard Analyses  Location > Enter maintenance plant 1000 > Analysis period 01/1998 - current month > Execute Press “Switch drilldown” button, activate equipment Select Actual costs column and press button Sort ascending

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12 Summary and Outlook

Contents:  Summary of business processes covered in this course  Summary of how Plant Maintenance is integrated  Overview of follow-up courses and their business processes



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12.2 Summary and Outlook: Business Processes

 Business processes  Integration of Plant Maintenance  Overview of follow-up courses

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12.3 Summary and Outlook: Unit Objectives

At the conclusion of this unit, you will be able to:  Describe the most important business processes in

Plant Maintenance and the steps involved  List the contents of the follow-up courses  Provide an overview of how Plant Maintenance is

integrated



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12.4 Course Overview Diagram

Course overview

External services

Navigation

Work clearance management

Plant Maintenance organization

Preventive maintenance

Technical objects

Refurbishment

Breakdown maintenance

Reporting and analysis

Corrective maintenance

Summary and outlook



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12.5 Business Process: Breakdown Maintenance

1 2

• Technical object • Description

Notification

1

3

• Work to be performed • Material • Internal/external resources • Tools

Planning

• Order release • Printout

Scheduling

4

2

Execution Execution

5

3

Completion

• Date • Malfunction

• Capacity leveling • Availability check

• Planned/unplanned material withdrawal • External procurement

• Time confirmation • Order settlement • Technical completion • Technical confirmation

History

Material Material usage, usage, orders, orders, notifications, notifications, PMIS, PMIS, usage usage list list 

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12.6 Business Process: Corrective Maintenance

1

• Technical object • Description

Notification

2

Planning

3

Scheduling

4

Execution

5

Completion

• Date • Malfunction

• Work to be performed • Internal/external resources

• Order release • Printout

• Material • Tools

• Capacity leveling • Availability check

• Planned/unplanned material withdrawal • External procurement • Time confirmation • Order settlement • Technical completion • Technical confirmation

History

Material Material usage, usage, orders, orders, notifications, notifications, PMIS, PMIS, usage usage list list 

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12.7 Business Process: External Assignment as Individual Purchase Order Invoice verification

Order 901760

Plant Maintenance

0010 Operation Company

Invoice

MDO

Purchase requisition Actual costs

Inventory management

Vendor

Purchasing

Purchase order 1 Charlton Ltd

2

Goods receipt 

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12.8 Business Process: External Company Work Centers Activity type planning 2000 Cost center Activity type

4010 4010 4010 4050 4100 4100 4100 4200 4200

Work center FR01 Quick & Co. Cost center Control key Activity type

Purchase order No. 45000125 1

Quick

4050 PM01 F01

M

Cost center 4050 Quick & Co.

4200 4200 …….. ……..

1410 1411 1412 F01 1411 1412 1420 MST FST RUE PER

Rate

32.50 33.80 75.00 62.70 33.80 55.75 33.90 69.00 12.00 45.00 80.00

01/01/98 - 06/30/98

150 manual worker hours at $ 62.70 Account assignment: Cost center 4050



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12.9 Business Process: External Services

Order 901760

Purchase requisition 0010 PM03 Lay steel pipe

Service specifications 01

Digging 01 02

02

Lay steel pipe 01 Tapping sleeve 02 Supply pipe



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12.10 Business Process: Work Clearance Management

Order Work approval Work clearance application Operational work clearance document

Order

Further applications

Enhanced model



Work clearance application Operational work clearance document

Standard model

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12.11 Business Process: Preventive Maintenance with Cycle

1999

94

96 98

1997 2000

I must perform the same inspections at regular intervals.



Inspection of "Portable fire extinguishers"

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12.12 Business Process: Preventive Maintenance with Strategy

External visual inspection

Internal visual inspection

Check gear teeth for wear Which parts must be maintained at which intervals? 

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12.13 Business Process: Refurbishment Customer Production

Procurement

Scrapping Material Material with/without with/without serialnumber number serial Condition"C2" "C2" Condition Quantity>>11 Quantity



Warehouse

Workshop

Material Material with/without with/without serialnumber number serial Condition"C3" "C3" Condition Quantity>>11 Quantity

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12.14 Summary and Outlook: Integration of Plant Maintenance

 Business processes  Integration of Plant Maintenance  Overview of follow-up courses



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12.15 Integration of Plant Maintenance with Other Areas (1)

Materials MaterialsManagement Management   

Storage of spare parts Procurement of direct material Procurement of external services

Production 

Availability of machine work centers



Production resources/tools

Cost Cost accounting Accounting   

Cost centers Internal activity allocation Order settlement

Project Controlling   

Maintenance projects Maintenance budget

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12.16 Integration of Plant Maintenance with Other Areas (2) Financial Accounting  

G/L account system Invoice receipt

Asset Accounting   

Tangible assets Acquisition values Net values

Human Resources 

Entry of working time

Sales and Distribution 

Maintenance of external devices

Quality Assurance 

Maintenance of test equipment

Investment Management  

Processing of investments

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12.17 Summary and Outlook: Overview of Follow-Up Courses

 Business processes  Integration of Plant Maintenance  Overview of follow-up courses



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12.18 LO805 - Structuring and Managing Technical Objects Course overview Functional locations (follow-up functions) Equipment (follow-up functions) Bills of material 3 days

Serial numbers Structuring objects using application examples Measuring points and counters Additional functions (including assignment of documents, CAD interface, status management, warranties, partners and addresses, data transfer, archiving)



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12.19 LO810 - Preventive Maintenance and Service Course overview Managing task lists Maintenance planning with cycle: Order Maintenance planning with cycle: Notification Maintenance planning with cycle: Service entry sheet 3 days

Maintenance plan-based sales of services Time-based maintenance planning with strategy Performance-based maintenance planning Maintenance planning with several counters Condition-based maintenance Maintenance plan-based test equipment management



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12.20 LO815 - Maintenance Processing: Operational Functions Course overview Notifications (including creation of notification types, configuration of tab pages, catalogs)

Planning (including creation of order types, work centers, capacity planning)

3 days Control (including availability checks, scheduling, permits, workflows, printing)

Completion (including confirmation parameters, history, CATS)



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12.21 LO816 - Maintenance Processing: Controlling and Reporting Course overview Costs in maintenance process Settling orders 3 days

Budgeting and cost planning (Including linking maintenance orders to Project System, investment management, investment orders)

Plant Maintenance Information System (Including creating a new key figure within a new info structure)

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12.22 LO820 - Work Clearance Management (WCM) Course overview Introduction WCM Objects Permits 3 days

Tagout/lockout Order processing Further functions Customizing



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12.23 Summary and Outlook: Unit Summary

 This Level 2 course has covered the most important

business processes in Plant Maintenance.  The follow-up courses concentrate on more specific

topics, with additional business processes and Customizing.  Plant Maintenance is integrated with other R/3

applications in many ways.



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13 Appendix

Contents:  Menu paths  ASAP



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13.2Menu Paths and Transactions Task /

Menu Path

Transaction Display task list For general task list - IA07

SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Task Lists – Task Lists – General Maintenance Task Lists – Display

For equipment - IA03

SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Task Lists – Task Lists – For Equipment – Display

For functional location - IA13

SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Task Lists – Task Lists – For Functional Location – Display

Display work center IR03 Settle order (single) KO88 Change order IW32 Create order IW31 Display order IW33

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Environment – Work Centers – Work Center – Display SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Environment – Order Settlement – Single SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Order – Change SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Order – Create (General) SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Order – Display

Order - list editing

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Order – List Editing

IW38

- Change

IW39

- Display

IW40

- Display (Multi-Level)

Create purchase order

Logistics – Materials Management – Purchasing – Purchase Order – Create – Vendor Unknown

ME21 / ME21N Create single cycle plan IP41 Change equipment IE02 Create equipment IE01 (C) SAP AG

SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Maintenance Plans – Create – Single Cycle Plan SAP menu – Logistics – Plant Maintenance – Technical Objects – Equipment – Change SAP menu – Logistics – Plant Maintenance – Technical Objects – Equipment – Create LO100

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Task /

Menu Path

Transaction Display equipment IE03

SAP menu – Logistics – Plant Maintenance – Technical Objects – Equipment – Display

Equipment - list editing

SAP menu – Logistics – Plant Maintenance – Technical Objects – Equipment – List Editing

IE05

- Change

IE08

- Display

Overall completion confirmation

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Entry – Overall Completion Confirmation

IW42 Create maintenance request IW26 Display catalog QS42 Enter services ML81 Display material MM03 Display material BOM CS03 Material where-used list IW13

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – Create (Special) – Maintenance Request SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Environment – Catalog – Display SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Services SAP menu – Logistics – Plant Maintenance – Technical Objects – Material – Display SAP menu – Logistics – Plant Maintenance – Technical Objects – Bill of Material – Material BOM – Display SAP menu – Logistics – Plant Maintenance – Maintenance Processing – History – Material WhereUsed List

Notification - list of tasks

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – List of Tasks

Change notification

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – Change

IW22 Display notification IW23 Notification - list editing

IW28 IW29 IW30 Notification - list of activities (C) SAP AG

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – Display SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – List Editing - Change - Display - Display (Multi-Level) SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – List of LO100

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Task /

Menu Path

Transaction Activities Notification - list of items

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – List of Items

Display serial numbers

SAP menu – Logistics – Plant Maintenance – Technical Objects – Serial Numbers – Display

IQ03 Standard analyses

SAP menu – Logistics – Plant Maintenance – Information System – Standard Analyses

Create malfunction report

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – Create (Special) – Malfunction Report

IW24 Create strategy plan IP42 Create activity report IW25 Change functional location IL02 Create functional location IL01 Display functional location

SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Maintenance Plans – Create – Strategy Plan SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Notification – Create (Special) – Activity Report SAP menu – Logistics – Plant Maintenance – Technical Objects – Functional Location – Change SAP menu – Logistics – Plant Maintenance – Technical Objects – Functional Location – Create

IL03

SAP menu – Logistics – Plant Maintenance – Technical Objects – Functional Location – Display

Functional location list editing

SAP menu – Logistics – Plant Maintenance – Technical Objects – Functional Location

IL05

- Change

IL06

- Display

Functional location structural display

SAP menu – Logistics – Plant Maintenance – Technical Objects – Functional Location – Structural Display

IH01 Goods movement MB11 Goods receipt MB31 Refurbishment goods receipt IW8W (C) SAP AG

SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Goods Movement – Goods Movement SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Goods Movement – General Goods Receipt SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Goods Movement – Refurbishment Goods Receipt LO100

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Task /

Menu Path

Transaction Change maintenance plan IP02 Display maintenance plan IP03 Schedule maintenance plan IP10 Deadline monitoring for maintenance plan IP30 Change maintenance strategy IP11 Display maintenance strategy IP12 Maintenance scheduling overview (graphical) IP19 Maintenance scheduling overview (list) IP24 Time confirmation individual entry IW41 Time confirmation collective entry with selection IW48 Time confirmation collective confirmation without selection IW44

(C) SAP AG

SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Maintenance Plans – Change SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Maintenance Plans – Display SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Scheduling for Maintenance Plans – Schedule SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Scheduling for Maintenance Plans – Deadline Monitoring SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Maintenance Strategies – Change SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Maintenance Strategies – Display SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Scheduling for Maintenance Plans – Scheduling Overview – Graphical SAP menu – Logistics – Plant Maintenance – Preventive Maintenance – Maintenance Planning – Scheduling for Maintenance Plans – Scheduling Overview – List SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Entry – Individual Time Confirmation SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Entry – Collective Time Confirmation – With Selection SAP menu – Logistics – Plant Maintenance – Maintenance Processing – Completion Confirmation – Entry – Collective Time Confirmation – Without Selection

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13.3 ASAP

Contents:  Components of TeamSAP

 ASAP Roadmaps  Major implementation tools

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13.4 ASAP: Business Scenario

 The implementation team analyses the tools and

services provided by SAP to facilitate the implementation of SAP software.

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13.5 ASAP: Objectives

At the conclusion of this unit, you will be able to:  Describe the components of TeamSAP  List and briefly describe the five phases of the

ASAP Implementation Roadmap  Discuss the main tools available for

implementing SAP software

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13.6 TeamSAP Components People: Solutions expertise Quality    

Processes :

SAP Consulting partners Complementary software partners Technology & hardware partners

AcceleratedSAP Consistency  

Products



AcceleratedSAP Roadmaps or powered-by methodologies SAP Review Program Support, services & training

Products : The Business Framework Strengths    





SAP product family Complementary software products Products from technology partners Industry solutions

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TeamSAP involves coordinated interaction between the groups involved in the implementation environment of the products concerned.

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13.7 AcceleratedSAP: Implementation Planning

ASAP Roadmap Continuous Project Preparation Business Blueprint

 Project Management  Change Management  Risk analysis  Review

Final Preparation

Realization

Improvement Go Live & Support

Methodology

 Implementation Assistant  Q&Adb

Projectrelated knowledge

Tools

 Implementation Guide  Profile Generator

Services

 Transport System

Consulting, Consulting, licensing, licensing, training training material, material, support, support, project project reviews reviews 

SAP AG 1999

SAP recommends that you use ASAP as a standard methodology for implementation planning and for implementing SAP software. The ASAP Roadmap provides a step-by-step guide to implementation.  During the five phases of an ASAP project, the results of each phase are recorded in specific documents. This is particularly important in Phase 2. 

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13.8 AcceleratedSAP Implementation Roadmap

ASAP Roadmap Continuous

Project Preparation Business Blueprint



  



 

Final Preparation Realization

Improvement Go Live & Support

SAP AG 1999

Phase 1: Project Preparation - The primary focus of Phase 1 is getting the project started, identifying team members and developing a high-level plan. Phase 2: Business Blueprint - The primary focus of Phase 2 is to understand the business goals of the enterprise and to determine the business requirements needed to support these goals. Phase 3: Realization - The purpose of this phase is to implement all the business and process requirements identified in the Business Blueprint. You configure the system step-by-step in the work packages Baseline and Final Configuration. Phase 4: Final Preparation - The purpose of this phase is to complete testing, end-user training, system management and cutover activities. Critical open issues are resolved. When you have successfully completed this phase, you will be ready to run your business in your production system. Phase 5: Go Live and Support - Transition from a project-oriented, pre-production environment to a successful and live production environment. The new ASAP Roadmap (available as of Release 4.6A), helps integrate all existing ASAP Roadmaps into one "configurable" one. It is based on the products R/3, BW (Business Information Warehouse), APO (Advanced Planner & Optimizer), CRM (Customer Relationship Management encompassing Mobile Sales/Mobile Services), and B2B (Business to Business Procurement) and provides a single implementation solution within ASAP for all SAP software.

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13.9 Global ASAP  Implementation strategy

 Change management

 Global definition of business  Manage global activities processes  Legal requirements  Global system topology  Standardization of business processes

Maintenance & Support Program Set-Up

Business Blueprint

Realization Rollout ASAP Roadmap Continuous

Project Preparation



Business Blueprint

Realization

Final Preparation

Improvement

Go Live & Support

SAP AG 1999

SAP has developed Global ASAP as the standard implementation methodology for the global implementation of SAP software. The basic concept of Global ASAP is to map all activities that do not take place at local level onto a special structure called the Global Roadmap. This Roadmap is structured according to the AcceleratedSAP principle and includes How-to's, accelerators, modeling methods and tools. The Global Roadmap is linked to each Roadmap for projects at local level.  A global implementation strategy involves defining a pre-configured corporate system or global template. The global template is the sum of all enterprise-specific configuration and Customizing settings, and models that are included in one SAP System and provide a reference for live systems at the global and local levels (individual companies and plants). This implementation approach is also referred to as the global template rollout of the SAP System.  The Global ASAP Roadmap consists of four phases:  Global Program Set-Up  Global Business Blueprint  Global Realization  Global Maintenance & Support 

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13.10 IMG: Tasks

IMG

•The IMG contains documentation for each activity. •The activities can be carried out directly. •Functions for project management and project documentation are available.

Global settings Countries Currencies Calendars

SAP Documentation Concept Recommendations Requirements Activity WinHelp



Project Management

Activities Open Customizing transactions

Status/activity data Scheduling Resources Microsoft Project interface

Project Documentation Efficiently organized using notes Use Microsoft Word

SAP AG 1999

The IMG contains all Customizing activities you need to implement application components. You can create Customizing projects in an SAP System, to help structure and manage an implementation project. You can also record cross-project documentation.  You can create an IMG for each project.  From a Project IMG you can work on Customizing transactions, project documentation, crossproject documentation, and information on project management.  

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13.11 CustomerCustomer-Specific Configuration

ASAP-IMG link

Manually

SAP Reference IMG

Generate Customizing Projects

Customizing transactions



 









Project IMGs

Project documentation

Generate Project IMG Views

Project IMG views

Project management

SAP AG 1999

The IMG acts as a checklist of the Customizing activities that your enterprise should complete to implement an SAP System. The IMG is hierarchically structured. The structure of the IMG and the IMG tools (for example, allocating resources such as project members and the MS Project interface) help your project team to work through the Customizing activities in a rational sequence. For the realization, you can divide the scope of the Reference IMG into different projects, which, in turn, are assigned to Project IMGs. Use a Project IMG to work on Customizing transactions, project and cross-project documentation, as well as information on project management. You can create views to improve the structure of a Project IMG. You can use these views to edit Customizing transactions, project and cross-project documentation, and information on project management, in line with the Project IMG. As of Release 4.6, you can use the ASAP-IMG link in the Q&Adb to create project views. This transfers the project scope set in the Question & Answer database (Q&Adb) to the R/3 System. The views generated by the ASAP-IMG link contain Customizing activities for the processes set in scope in the Q&Adb. To use the ASAP-IMG link, a Customizing project must already exist in the R/3 System.

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13.12 Accelerated Industry Solutions: Steps Industry-specific details in ASAP and documentation Model-based presentation of the industry solution

Industry-specific Business Blueprint

Industry-specific Customizing in IMG and CATTs

Preconfigured Industry System

Industry-specific business components

Business framework component

Accelerated Solution 

SAP AG 1999

System documentation and the ASAP Question & Answer database contain industry-specific information and are the ideal places to start looking for information.  Model-based presentations of industry-specific business processes help you analyze the business processes you have selected. Event-driven process chains (EPCs) are available for several industries (for example, the automotive and pharmaceutical industries) and are integrated in the SAP Reference Structure. A structure is available for each industry in the ASAP Question & Answer database, and helps you to produce an industry-specific Business Blueprint (Phase 2 of the ASAP Roadmap).  Industry-specific Customizing involves integrating default Customizing parameters for a specific industry in the IMG. SAP has documented this process in the IMG. You can use the Computer Aided Test Tool (CATT) which is also integrated in the system to transfer industry-specific master data structures to the system. Test programs (CATTs), named after the above tool, are provided for the industry-specific business cases defined by SAP. This collection of tools is known as Preconfigured Industry Systems.  Industry-specific business solutions are integrated as business components in the business framework. Implementation in the system can also be a ready-to-work solution. The main feature of such a solution is the delivery of a combination of software and hardware required to install an SAP System. 

(C) SAP AG

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13.13 Implementation Planning and Tools: Summary

You are now able to:  Describe the elements of TeamSAP  List and briefly describe the five phases of the

ASAP Implementation Roadmap  Discuss the major tools that support an SAP

implementation

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SAP AG 1999

(C) SAP AG

LO100

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