Sap Plant Maintenance Pm Business Blueprint Bbp
December 24, 2016 | Author: SrinivasBurugupalli | Category: N/A
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Vedanta Alumina Limited
Plant Maintenance
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SAP ECC 5.0 IMPLEMENTATION
Business Process Blueprint
Version No - 1.3
SAP R/3 IMPLEMENTATION BUSINESS BLUEPRINT Plant Maintenance Prepared by Vishal Rathore
Checked by Pinaki Roy
Reviewed By Mr. Krishna Mr. Coumar Mr. Manna
Signature
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Approved By Mr. Swain Mr. Kanada
Signature
Date 24.01.2006
Vedanta Alumina Limited
Plant Maintenance
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Business Process Blueprint
Version No - 1.3
CONTENTS OBJECTIVE OF BUSINESS BLUEPRINT PHASE
3
SCOPE OF BPBP DOCUMENT
6
PLANT MAINTENANCE IN SAP - OBJECTIVE
7
SECTION I
8
SCOPE OF PLANT MAINTENANCE MODULE IN VAL
8
SECTION II
11
ORGANIZATION STRUCTURE
11
SECTION III
29
TO-BE PROCESSES
29
LIST OF REPORTS
82
SECTION IV-APPENDIX
86
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Business Process Blueprint
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OBJECTIVE OF BUSINESS BLUEPRINT PHASE This document is the outcome of the As-Is study, Discussion at Training and during the To-Be process and business process requirement analysis for the Vedanta Alumina Limited. Based on this As-Is coupled with inputs from the core team members during To-Be discussion, we arrived at the Business Processes, which are incorporated in the Business Blue Print. The aim of this document is to map the best business processes related to the Plant Maintenance module in SAP ECC 5.0. This document is to be studied by core team members & process owners from Vedanta Alumina Limited. The preparation of this document is an essential precursor to prototyping and testing. The development work will start once process owner’s approval for this Blue Print is obtained followed by a corporate presentation to the senior management team, Vedanta Alumina Limited. This document will be used for configuring Plant Maintenance module in SAP implementation. Document is based on discussions/presentations between representatives of VAL & PWC. In other words it contains 1. SAP Organization Model in context of existing business scenario and future requirements/issues as envisaged by VAL. 2. Mapping of business processes/issues brought forward by PwC & VAL, with SAP functionality 3. Gaps & issues emerged during the discussion between VAL & PwC 4. Business Process Flows mapped in SAP as per the scope defined.
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5. Closure of Mapping Phase and start of Piloting Phase of implementation
A pictorial presentation of complete SAP implementation is depicted in the following page:
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Business Process Blueprint
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Business Process Blueprint
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SCOPE OF BPBP DOCUMENT The objective of this Blue Print presented to the Project Sponsor is to document the following: a)
b) c)
Business Requirements of VAL that need to be translated into SAP. This has been prepared by SAP consultants team members on the basis of As-Is document, factory visit & discussions between PwC SAP consultants and VAL core team members. SAP Gaps as identified by PwC Team w.r.t. The present scope of implementation and Business Requirements of VAL. Details of SAP New Business Process description supported by Process Flow diagram w.r.t. Different SAP process Processes”.
indicating the desired “To be
In order to bring the clarity and better understanding, the document has been divided in five sections:
SECTION I : Scope of SAP Plant Maintenance module for the project SECTION II : Organization structure SECTION III : Master Data Management, As-Is/ To-Be Business processes, and Gaps identified for business processes as per SAP. SECTION IV: Appendix-Process Flow Diagrams.
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Plant Maintenance in SAP - Objective Ø To have Reliable Equipments with low MTTR and high MTBF Ø To have Predictive and Condition –based plans that help to improve equipment availability. Ø To eliminate repetitive breakdowns and thereby reduce wastage of valuable resources Ø To have a Preventive Maintenance Plan in place that helps to maintain Equipment Health. Ø To eliminate the need to pull out data from different systems for reporting purposes. Ø To draw a long-term plan for Spares requirement and also help in Budgeting. Ø These objectives will be obtained by Ø By detailed analysis of downtimes and designing a Corrective Action Plan based on this analysis. Ø By having up to date cost figures (Plant-wise/Location-wise/Equipment-wise) for better maintenance decision-making Ø
By analysing usage data on components and services related to maintenance.
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SECTION I Scope of Plant Maintenance Module in VAL PARTICULARS Master 1.1 General Master Records 1.1.1 Material Master 1.1.2 Material BOM 1.1.3 Work Center 1.1.4 Service Master 1.2 Plant Maintenance 1.2.1 Technical Objects (Structuring of Technical Systems) 1.2.2 Measuring Points & Measuring Documents 1.2.3 Warrantees 1.2.4 Permits 1.2.5 Task Lists 1.2.6 Maintenance Strategy 1.2.7 Maintenance Plans Business 2.1 Plant Maintenance 2.1.1 Breakdown/Routine Maintenance Processing
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ALUMINA
POWER
X X X X
X X X X
X X X X X X X
X X X X X X X
X
X
MM
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PARTICULARS 2.1.1.1 Notification 2.1.1.2 Order 2.1.1.3 Material Movements 2.1.1.4 Completion Confirmation 2.1.2.5 Confirmation of external services through service sheet 2.1.1.6 Settlement and Completion 2.1.1.7 Evaluations: Information System 2.1.2 Preventive / Shut Down Maintenance Processing 2.1.2.1 Maintenance Planning 2.1.2.2 Worklist 2.1.2.3 Notification 2.1.2.4 Deadline Monitoring 2.1.2.5 Order 2.1.2.6 Material Movements 2.1.2.7 Completion Confirmation 2.1.2.8 Settlement and Completion 2.1.2.9 Evaluations: Information System 2.1.3 Refurbishment Processing in Plant Maintenance 2.1.3.1 Order 2.1.3.2 Material Movements 2.1.3.3 Completion Confirmation 2.1.3.4 Settlement and Completion 2.1.3.5 Evaluations: Information System CONFIDENTIAL
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ALUMINA
POWER
X X X X X X X
X X X X X X X
X X X X X X X X X
X X X X X X X X X
X X X X X
X X X X X
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PARTICULARS 2.1.4 Development/Improvement/Re-Design Orders 2.1.5 Calibration Orders 2.2 Inventory Management 2.2.1 Goods Movements 2.2.1.1 Reservation 2.2.1.2 Purchase requisition 2.2.1.3 Goods Receipt 2.2.1.4 Stock Transfers / Trans. Postings 2.2.1.5 Goods Issue Cross-Application Components 3.1 Classification System 3.1.1 Characteristics 3.1.2 Classes 3.1.3 Classification
ALUMINA
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POWER
X X
X X
X
X
X
X
X X X
X X X
PM/QM
MM MM MM
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Section II Organization Structure Plants The plant is an operating area or branch within a company. The plant is assigned to a single company code. A plant has its own material master data. You can maintain data at plant level for the following views on a material master record in particular: MRP, Purchasing, Storage, Work scheduling, Production resources/tools, Forecasting, Quality management, Sales, Costing. As per discussion with Finance & Materials, there will be only four Company Codes and four plants will be created which may be as follows: VAL Alumina VAL Power VAL Smelter VAL JV
1000 2000 3000 4000
Out of this, the VAL Alumina Plant (1000), VAL Power Plant (2000) will have complete PM Implementation while the VAL smelter Plant (3000) and JV (4000) will only have PM basic organization structure.
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Maintenance Plant In Plant Maintenance, a distinction is made between the organizational units "planning plant" and "maintenance plant". •
Maintenance plant In a maintenance plant, you can manage technical objects and main work centers.
•
Planning plant In the planning plant, maintenance task lists are defined for the respective maintenance plants, material planning is carried out on the basis of bills of material in task lists and orders, maintenance plans are managed and scheduled, maintenance notifications are created and maintenance orders can be handled.
With discussion for the Organization Structure for Maintenance Planning, it has been decided to follow the based on the Material Management Plant Code. Since maintenance Planning is independent of all four plants, hence there will be four maintenance planning plants in Plant Maintenance Organization Structure. They are as follows:
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MAINTENANCE PLANT
DESCRIPTION
1000
VAL Alumina Maintenance Plant
2000
VAL Power Maintenance Plant
3000
VAL Smelter Maintenance Plant
4000
VAL JV Maintenance Plant
MAINTENANCE PLANNING PLANT
DESCRIPTION
1000
VAL Alumina Maintenance Planning Plant
2000
VAL Power Maintenance Planning Plant
3000
VAL Smelter Maintenance Planning Plant
4000
VAL JV Maintenance Planning Plant
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Locations A location is the physical location to identify where the equipment lies. This data helps the Plant Maintenance person to identify where the equipment is located. Here location, plant section, room number etc. can be mentioned. Proposed locations for Vedanta Alumina Limited are as follows: For Alumina Plant (1000) Location
DESCRIPTION
RED
Red Area
WHT
White Area
UTL
Utilities
NPA
Non Plant area
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For Power Plant (2000) Location
DESCRIPTION
TGU
Power Generation
BLR
Steam Generation
BOP
Balance of Plant
For Mining Plant (4000) Location
DESCRIPTION
MIN
Mining
CRG
Crushing
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Planner Group Planner groups or maintenance planning groups must be defined separately for each planning plant. Depending on the size and structure of your company, a maintenance-planning group may be an individual department (for central work preparation), a group of skilled craftsmen or a workshop. Every piece of equipment and functional location can be allocated to a maintenance-planning group. Maintenance planning groups can also be used for evaluation purposes. In Vedanta Alumina Limited we have identified FOUR planner groups for each plants For Alumina Plant (1000) Planner Group
DESCRIPTION
101
Mechanical Planner Group
102
Electrical Planner Group
103
Instrumentation Planner Group
104
Civil planner Group
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For Power Plant (2000) Planner Group
DESCRIPTION
201
Mechanical Planner Group
202
Electrical Planner Group
203
Instrumentation Planner Group
204
Civil planner Group
For Mining Plant (4000) Planner Group
DESCRIPTION
401
Mechanical Planner Group
402
Electrical & Instrumentation Planner Group
404
Civil planner Group
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Functional Location category Functional Location Category to be used – “M” – Technical System Standard
Functional Location Structure Indicator We shall be using the following Structure Indicator for Functional Location Labelling: STRUCTURE INDICATOR
DESCRIPTION
STRUCTURE
VAL01
Indicator for Alumina Plant
NNNN--AAA-AAA-XXX-XXXX-XXXXX
VAL02
Indicator for Power Plant
NNNN- AAA-XXX-XXX-XXX-XXX
VAL03
Indicator for Mining Plant
NNNN- AAA-XXX-XXX-XXX-XXX
(A- Alpha, X- Any character, N-Numeric)
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Example: 1000-RED-DIG-TR0-DIGV-DIG01 1000 – Vedanta Alumina Plant DIG – Digester Area TR0 – Train 0 Area DIGV – Digestion Vessel DIG01 – Digester 01
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Equipment Categories and Equipment Codification Equipment Categogy for all the equipment will be used as ‘M’ It has been decided that the Equipment Code will be Externally generated for easy identification and the logic for that code will be XX Main Group
XXX Sub-Group
NNNN Number
Spare Parts / Assemblies / Components codification All the spare parts, assemblies, components, consumables for maintenance will be defined as material in SAP for taking them in inventory and the material code will be externally generated. Logic for the material code is XX Major Group • • •
XX Sub Group
XXX Sub- Sub Group
XXXXX Material No
The codification is external. 12 digit codification, split as mentioned above. It is going to be all numeric
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1. 2. 3. 4. 5.
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For bearings, the codification will be strictly with the engineering department. Flag in the system for insurance spares. Flag for the regular inventory items. Flag for the value capture of all the materials. For initial project spares, value will be taken as zero and split valuation will be used for it.
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Technical Object Types This implies a division of a technical object for precise description. All equipments at VAL would be categorized into various Technical Object Types. An indicative list of technical objects is given below. Alumina Plant Technical Object
Technical Object
Technical Object
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Power Plant Technical Object
Technical Object
Technical Object
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Catalog Profile Combination of code groups, which determine from a functional viewpoint, which code groups can be used for a particular technical object. The following catalogs would be used for VAL. Common catalog profile will be used for different technical object types. n Coding - D n Object parts – B n Problem/Event Codes – 4 n Cause Codes – 5 n Activity Codes – A We shall be using common catalog profile for all equipments. Details of the catalogs would be maintained as follows: Ø Coding: Coding of breakdowns as Serious/Semi-serious/Normal Ø Object Parts: All critical Mechanical and Electrical parts would be configured for each of the technical object types defined. Ø Problem/Event Codes: All problems that normally occur or might occur would be listed for each type of Technical Object. Ø Cause Codes: All probable causes of the events/problems listed above would be configured for each technical object type. Ø Activity Codes: The normal activities (generic) carried out for attending to the problems would be configured here. CONFIDENTIAL
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Example:
Technical Object Type : Pump Object Parts
Problems
Causes
Activities
Impeller
Impeller Broken
Improper Cleaning
Cleaned
Bearing
Impeller Jammed
Lubrication Failure
Machined
Casing
Bearing Damaged
Life Expiry
Rewinding Done
Shaft
Abnormal Sound
Impeller nut Loose
Reset
Misalignment
Replaced
Pressure Low Shaft Damaged
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Notification Types Various Notification Types would be configured in the System to take care of the various types of job requirements.
NOTIFICATION TYPE
DESCRIPTION
M1
Maintenance Request (Predictive w/o production loss)
M2
Breakdown Report (Breakdown Maintenance with production loss)
M3
Activity Report (Preventive Maintenance)
M5
Improvement (Modification/Development/Re-Design) Notification
M6
Safety Notification
M7
Shutdown Notification
M8
Calibration Notification
M9
Workshop Notification
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Maintenance Order Types Seven different types of Maintenance orders will be defined for the various types of maintenance/repair activities to be carried out.
MAINTENANCE ORDER TYPE
DESCRIPTION
PM01
Maintenance order w/o production loss
PM02
Breakdown order with production loss
PM03
Preventive maintenance order
PM04
Re-furbishment Order
PM05
Improvement (Modification/Development/Re-Design) order
PM06
Safety Order
PM07
Shutdown Order
PM08
Calibration Order
PM09
Workshop Orders
PM10
Annual Maintenance Contracts
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Assignment of Notification Types to Order Types Notification type
Order type
M1
PM01
M2
PM02
M3
PM03
M5
PM05
M6
PM06
M7
PM07
M8
PM08
M9
PM09
There will be no notification for refurbishment orders & Annual Maintenance Orders.
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SECTION III
To-Be Processes Plant Maintenance Processes The Business Blue Print is divided into various sections as defined by the different processes as discussed during to-be and Expectation from SAP. These processes are: Routine/Predictive Maintenance Breakdown Maintenance Preventive Maintenance (based on duration and measuring point) Refurbishment Spares Improvement / Development / Modification / Re-design Maintenance Shutdown Maintenance (Planned maintenance) General Maintenance (to be done through maintenance request) Annual Maintenance Orders Maintenance Budgeting (Through FI/CO Module) Condition Monitoring (Through measuring points/counters) Spare Part Planning Report Analysis To carry out these processes, certain Masters are required to be maintained prior to carry out the Transactions and Reports.
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Sl. No.
Process Name
1.0
Masters
Mode
Process Description/remarks
Gap (Y/N)
Remarks
N
Will be done with the coordination of MM
All Spare Parts, Consumables used in building of machine or repair will get a unique material code. This code will be unique for the whole organisation and will not change at Plant level. Basic data of the materials will be maintained at client level while the other data will be maintained at purchase organization and plant level.
1.1
Spare Parts, Components, Assemblies
Fully system supported
The material master for spare parts will have several views like Basic Data, Purchasing View, MRP, Accounting view etc. The Spare Parts, which are accepted after inspection will be subjected to Quality Inspection. For such material Quality Management View will be activated and necessary master date will be created for the automatic inspection lot creation and results recording and usage decision for the Spare parts. For VED analysis (V-Vital, E-Essential, D-Desirable) one field will be used in the material master of the spares so that this analysis can be done. CONFIDENTIAL
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Sl. No.
Process Name
Mode
Process Description/remarks
Gap (Y/N)
Remarks
N
Will be done with the coordination of MM
The spare part in SAP is maintained with the valuation category. In the valuation category, the valuation type is maintained. These valuation types can be damage, repair etc. Each of the valuation type has certain value attached to it. 1.2
1.3
Valuation type of Spare Parts
Catalog
Fully system supported
Fully system supported
During the maintenance activities, spare parts are replaced with new or repaired one. The defective spare parts are repaired also. In SAP, the maintenance and cost of repair of such defective spare parts is maintained using Refurbishment Order. Repaired part can be stored at different storage location. The activity is directly linked to MM as well. Hence the valuation class and type will be in accordance and consultation with MM. Catalogs are used to manage, uniformly define, and standardize information (for example, cause analysis for the failure of the machine) on a client-wide basis. The catalogs help in recording the information with ease and sorting out the activities as well. In the catalogs, each unit of information is assigned a unique alphanumeric code and an explanatory text. CONFIDENTIAL
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N
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Sl. No.
Process Name
Mode
Process Description/remarks
Gap (Y/N)
The different catalog types are Object Parts, Cause, Damage, Task, Activities, etc. The task and Activities are similar with different presentation structures. In Task Screen, for each task, Planned Start date, Planned Finish date, Completed By and Completion Date can be mentioned. In Activities Screen, Start Date and End Date can be mentioned.
1.4
Code Group
1.5
Functional Location Create / Change/Display Functional Location Master Data
Fully system supported
Fully system supported
Code groups are used to combine and structure codes within a catalog type. Code groups are used at client level to group codes that have the same contents or relate to one another, within a catalog type. Assigned codes to a group are called as Code Group.
Functional location is an organizational unit within Logistics, which structures the maintenance objects of a company according to functional, process-related or spatial criteria. A functional location represents the place at which a maintenance task is to be performed. A functional location represents an area at which an object can be CONFIDENTIAL
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N
N
Remarks
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Sl. No.
Process Name
Mode
Process Description/remarks
Gap (Y/N)
installed. The objects that can be installed at functional locations are called pieces of equipment Records can be kept of the maintenance tasks that are performed; technical data can be collected and evaluated over long periods of time and the costs of maintenance tasks can be monitored for the individual areas. Analysis can be carried out on the influence of usage conditions on the damage susceptibility of the pieces of equipment installed.
1.6
Equipment Master Fully Create/Change/Displa system y Equipment master supported Data
The use of equipment master records in the Plant Maintenance (PM) application component enables to define individual machine, motor as a piece of equipment. Equipment for which any maintenance activities are carried out, are maintained in the Equipment Master. The cost of maintenance of equipment based on type of maintenance can be monitored. If the equipment is very big, then equipment and sub-equipment can be created in SAP.
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N
Remarks
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Sl. No.
Process Name
Mode
Process Description/remarks
Gap (Y/N)
The Start up date field indicates the installation & commissioning date. This indicates the date on which the equipment is operational.
1.6.1
1.6.2
Start up & Acquisition Date
ABC Indicator
Fully system supported
Fully system supported
The Acquisition date indicates when the asset is purchased. The use of this date is for information as well as for deciding the ageing of the equipment so that the maintenance planning can be updated e.g. during the initial installation period the preventive maintenance requirement is lower but after years of usage, the requirement of preventive maintenance planning frequency increases. The ABC Indicator in an Equipment signifies the importance of that equipment in the manufacturing scenario. This helps in prioritising the maintenance planner to execute the maintenance activities in the plant. There will be four types for maintenance and one for calibration for the ABC Indicator as the outcome of the discussion: CONFIDENTIAL
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N
N
Remarks
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Sl. No.
Process Name
Mode
Process Description/remarks
Gap (Y/N)
A: Very high Production Loss B: Major Production Loss C: Minor Production Loss D: No production loss (Spare assembly) Q: Quality Loss (for Calibration Instruments) Warranties define the scope of the services that a company performs at a technical object in the event of damage or problems.
1.6.3
Warranty
Fully system supported
It is a commitment of the manufacturer, vendor, or retailer to guarantee services to a customer either free-of-charge or only charged in part, over a certain period of time.
N
The warranty period of the equipment can be mentioned in the equipment master. This gets pop up when a user wants to create maintenance order for the equipment during the warranty period. 1.6.7
Permits
Fully system supported
Agreement required depending on setting before an order may be released or technically completed. CONFIDENTIAL
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N
Remarks
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Sl. No.
Process Name
Mode
Process Description/remarks Permits are used to ensure that special approval must be obtained before orders are executed. Permits can be assigned to the following objects: •
Technical objects – functional locations and equipment
•
Orders
Permits can cover the following areas: •
The way the order is executed or the safety aspects involved Safety precautions for the employees and surroundings: Providing ear protection for employees or acidproof equipment, safeguarding the work area, installing a flameproof zone, work clearance certificate
•
How the execution of an order is organized Budget guarantee, approval of plant manager
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Gap (Y/N)
Remarks
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Sl. No.
1.7
Process Name
Budget
Mode
System supported
Process Description/remarks Budget for maintenance can be done at the maintenance cost center level. Apart from budget, we can also give the planned expenses for maintenance.
Gap (Y/N)
N
Cost center and budget will be done in CO module.
1.8
Classification Creation/change of Class and Characteristics
The classification system allows you to use characteristics to describe all types of objects, and to group similar objects in classes – to classify objects, in other words, so that you can find them more easily later. Fully system supported
You then use the classes to help you to find objects more easily, using the characteristics defined in them as search criteria. This ensures that you can find objects with similar or identical characteristics as quickly as possible. Characteristic is a property that describes and differentiates objects. Example: length, color, weight, etc.
CONFIDENTIAL
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Remarks Through FI/CO Module
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Class is an assembly of characteristics that can be attributed to a product (or to several similar products). It can also be defined as a grouping of similar products according to common characteristics Example – Pump class, Boiler class etc.
1.9
1.10
Maintenance Strategy Creation/Change of Maintenance strategy
Fully system supported
Work Center Creation/Change of Work centers
Fully system supported
A rule for the sequence of planned maintenance and predefined tasks. A maintenance strategy contains the maintenance packages that define the cycle in which the tasks must be performed, for example, every two months, every 5,000 km, every 500 operating hours. Maintenance strategies are obligatory in strategy plans. Work center describes the logical station where work is being carried out. The plant will have one or more work centers.
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Maintenance Task List Creation/Change of Task-lists 1.11
1.12
(For Preventive Maintenance, Shut down Activities, and Calibration)
Strategy Plan Creation/Change of Maintenance Plans
Mode
Fully system supported
Process Description/remarks Equipment Task List is the description of the procedure for maintaining a maintenance object called Equipment. Maintenance task lists is the generic term used for all task lists specifically to Equipment task list. A maintenance task list contains operation. The maintenance task list uses a strategy for planning of Equipment Maintenance for the defined period say weekly, monthly, quarterly etc. Operation can be processed internally or externally. The activities defined for an external operation are requested using orders.
Gap (Y/N)
N
There are two types of Equipment Task List: Equipment Task List and General Task List. Equipment task List can be attached only to one Equipment Task List. But General Maintenance Task List can be attached to several Equipments. The General Equipment task List is used for the Preventive Maintenance where the similar equipments undergo Preventive Maintenance Scheduling. Fully system supported
Strategy Plan defines the description of maintenance and tasks to be performed on maintenance objects. The dates and scope of the tasks are also defined here. CONFIDENTIAL
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(For Preventive Maintenance, Shut down Activities, Calibration
1.13
1.14
Scheduling for the Equipment
Equipment / Material BOM (Bill of Material) Creation/ Change of BOM
Process Description/remarks
Gap (Y/N)
A maintenance plan is structured based on a maintenance strategy. A maintenance plan contains one or more maintenance items, in which the maintenance objects to be maintained and the corresponding task list has been defined. The maintenance tasks to be performed on a due date are determined by the maintenance task list assigned to the maintenance item. The necessary maintenance orders are automatically generated for a due maintenance date.
Fully system supported
Based on the maintenance plan, we can schedule the Preventive/Shut down/Calibration Plan for the whole of the scheduling period or we can use deadline monitoring to carry out the scheduling of the Preventive Maintenance Orders for fixed period of say one month etc.
N
Fully system supported
Any equipment is made of some assemblies and the assemblies are further made of spare parts and small components down the level.
N
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The equipment BOM gives ready list available to record the critical spare part list for any equipment. The same list can be referred to create preventive maintenance planning. In the equipment BOM, create the spare part list, quantity and stock type (non-stock or stock item). This master helps in identifying for which material Purchase Requisition will be made or Reservation is created. For assemblies also we need to create BOM (Material BOM).
1.15
Measuring Points and Counters Creation/ Change of Measuring Points
Fully system supported
A physical or logical place at which a condition is described. Example can be Temperature inside a reactor, Speed of revolution of a wind wheel, the status is described using measurement readings, the operating duration of Diesel Generator etc. N Measuring points are stored in the SAP System as master data for the Equipment. It can work as a counter to record the duration, based on manufacturer guidelines, the Preventive Maintenance Orders can be generated for the same.
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Counter are defined as Measuring Point in SAP and Counter readings are taken at counters at particular intervals and in particular measurement units. For example, counter readings for kilometers driven, operating hours or electricity used.
2.0
Notification
Fully system supported
A key that determines the origin, content, and other features of maintenance activities. The Maintenance notification includes malfunction, activity reports and maintenance requests. It gives the equipment location data, malfunction start and end date/time, duration of total breakdown, priority etc.
N
Maintenance notifications document maintenance tasks completely, and make them available for analysis in the long term. You can use them for preliminary planning and execution of tasks.
3.0
Fully Maintenance Order system supported
Order is a task to perform within a company. The order specifies the type of task to perform, how and when it will be performed. It also defines the rules for the settlement of the costs. Maintenance order to be used whenever any cost is involved for CONFIDENTIAL
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maintenance activity, i.e., external services required or components required for maintenance. Orders will be used in Plant Maintenance Module for classifying different type of activities for an equipment, functional location etc. For the new purchased assets, Internal Order can be used for cost involved in purchasing, erecting and commissioning activities. These orders will be created in CO module.
4.0
External Services
Fully system supported
4.1
Creation of operation using PM03 control key
Fully system supported
External Services are the external support required from the expert for the maintenance of equipments. This process can be required for Preventive, Breakdown or any other type of maintenance. Hence this becomes a common process required for any maintenance activities. The different steps of confirming an external service are given below. In general, Plant Maintenance Internal control Key (PM01) is used. Wherever the external services are required, in the relevant CONFIDENTIAL
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operation of that order, the PM03 (Plant Maintenance External Services) control key is used. Using this key, the system requires the Service No. / Description, Quantity and price of the service. Based on the MM requirement for Purchase Requisition, certain fields are required to enter. On saving the order, the system creates the Purchase Requisition number for the external services. This PR number is used to create the Service Purchase Order by MM.
4.2
Confirming the External Services
Fully system supported
For confirmation of external services, Service Entry Sheet is used. The service entry sheet is created with reference to the Service PO. In the service entry sheet, the number or percentage of services is confirmed. Accordingly the data is updated in Controlling and Financial Accounting for releasing the payment for the external services.
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5.1
Process Name
Mode
Predictive Maintenance/ Fully Routine system Maintenance/Gene supported ral Maintenance
Notification by the user / maintenance in-charge of the machine (M1)
Fully system supported
Process Description/remarks There are many instances when based on the noise factor, heat dissipation etc. the prediction of machine failure can be made. In such cases, maintenance activities are carried using Predictive Maintenance. The decisive factor in this case is that there is no malfunction.
Gap (Y/N)
N
Here Predictive Maintenance Notification is created to record the damage cause, activities undertaken. User / maintenance in-charge creates a Predictive Maintenance Notification (Maintenance Request) based on the abnormal behaviour indicated in the machine during the operation in the machine. Notification type M1 is to be used. In this the status of the machine before and after malfunction, date and time of malfunction and priority etc. are defined.
N
The location and other necessary data get copied into the notification from the equipment master.
5.2
Create maintenance order from Notification
Fully system supported
After receipt of the notification, the maintenance department creates the Maintenance Order (Order Type - PM01) using the screen of notification in change mode. Then describes the CONFIDENTIAL
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screen of notification in change mode. Then describes the operations, requirement of spare parts for the maintenance activities in the order and Release for and issue of spares and confirming the activities. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.
5.3
Order Execution
Fully system supported
5.4
Order Completion Confirmation
Fully system supported
During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.
After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is CONFIDENTIAL
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confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully. You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and suboperations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.
5.5
View Costs
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed
N
5.6
Change / Complete Notification
Fully system supported
Notification will be closed after noting down all catalog & details of maintenance required to be recorded.
N
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5.7
Technically and Business Completion
Fully system supported
6.0
Breakdown Maintenance
Fully system supported
Process Description/remarks After confirmation for the maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile. When all the costs are settled and no further activities are pending against that order, business completion for the order is done. The Breakdown maintenance refers to the sudden failure of the machine to produce the desired results / output. An employee from production would use a malfunction report to report that: • A production system is not functioning properly. • Performance has reduced for a production system, or that the system is not functioning at all. • A production system is producing goods of poor quality. This is carried using a formal intimation by user department for the maintenance of the equipment. The record of total repair time is used to calculate Mean Time To Repair.
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Gap (Y/N)
N
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Process Name
Notification by the user of the machine (Malfunction Report M2)
Mode
Fully system supported
Process Description/remarks Like the Breakdown slip, here in SAP the user creates a breakdown notification to intimate the Maintenance Department for the breakdown in the machine. In this the user defines the status of the machine, date and time of breakdown and priority of the breakdown.
Gap (Y/N)
N
The location and other necessary data get copied into the notification from the equipment master.
6.2
Create maintenance order from Notification
Fully system supported
After receipt of the notification, the maintenance department creates the Maintenance Order (Order Type - PM02) using the screen of notification in change mode. Then describes the operations, requirement of spare parts for the maintenance activities in the order and Release for and issue of spares and confirming the activities. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.
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6.4
Process Name
Order Execution
Order Completion Confirmation
Mode
Fully system supported
Fully system supported
Process Description/remarks During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.
After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully. You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and subCONFIDENTIAL
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Gap (Y/N)
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operations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.
6.5
View Costs
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed
N
6.6
Change / Complete Notification
Fully system supported
Notification will be closed after noting down all catalog & details of maintenance required to be recorded.
N
6.7
Technically and Business Completion
Fully system supported
After confirmation for the maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile. When all the costs are settled and no further activities are pending against that order, business completion for the order is done.
CONFIDENTIAL
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7.1
Process Name
Preventive Maintenance
Preventive Maintenance order generation from schedule.
Mode
Fully system supported
Fully system supported
Process Description/remarks
Gap (Y/N)
Preventive maintenance is the scheduled / planned maintenance based on the manufacturer recommendation or own experience. Here a frequency called Strategy for Maintenance is maintained based on Duration or the operating hours. The activities unlike other maintenance are much clear in advance and are documented in the maintenance Task list. The spare parts as well can be planned and stocked for the periodic maintenance activities. In Preventive Maintenance, certain master data needs to be maintained. The task list, strategy plan, measurement counter (optional) etc. are maintained for equipment. Measurement Counter uses a class characteristics say operating duration. The counter is created for the equipment. For recording the status / data of the counter, measurement document is created. The equipment task list contains the list of operation and suboperations. The spare and consumables required for the completion of the maintenance operations can also be maintained CONFIDENTIAL
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in the task list. Based on the release of maintenance order, the reservation for the stock-able spares and consumables are created in the system. For non-stock spares, the PR is created from the maintenance order. The equipment plans are then scheduled (periodically) using deadline monitoring for a target period of say one month. The scheduling creates Preventive Maintenance Orders (Order type – PM03) automatically for the period.
7.2
Notification for recording activities Activity Report (M3)
Fully system supported
On the due date, the required spares can be issued from the store. Based on the order created, a notification is also generated by the system. The purpose to create a notification is to record the activities done during the Preventive Maintenance. Also it can be the ready reference for the activities left for future Maintenance. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.
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7.4
Process Name
Order Execution
Order Completion confirmation
Mode
Fully system supported
Fully system supported
Process Description/remarks During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.
After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully. You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and subCONFIDENTIAL
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Gap (Y/N)
N
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operations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.
7.5
View Costs
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed
N
7.6
Change / Complete Notification
Fully system supported
Notification will be closed after noting down all catalog & details of maintenance required to be recorded.
N
7.7
Technically & Business Completion
Fully system supported
After confirmation for the maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile. When all the costs are settled and no further activities are pending against that order, business completion for the order is done.
CONFIDENTIAL
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8.1
8.2
Process Name
Refurbishment Order
Mode
Fully system supported
Process Description/remarks Refurbishment order is the special order, which are used for the refurbishment of repairable spares. In the refurbishment order, contract a work centre to restore faulty repairable spares to full working order at a certain date. The repairable spares scheduled in the order are brought from a uniform initial condition to a uniform end condition. To distinguish the condition of damage to repair for spares different valuation types are used.
Fully system supported
Maintenance person will create a notification to intimate the workshop Department for the refurbishment in the component
Create Refurbishment Fully Order for the damage system spare supported Order Type (PM04)
Create the Refurbishment order with order type PM04. The order is created for the damaged Spare Part Material. The valuation type of spares is maintained in the Accounting 1 view in the material master.
Notification for Refurbishment (M4)
Gap (Y/N)
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Create appropriate operations with internal maintenance, consumables required for the Repair of the spare part. The valuation type present and future (after repair) is mentioned in the order. Release the order and save it.
During refurbishment of spare (outside SAP), consumables required will be issued against the reservation created in the order.
8.3
Order Execution
Fully system supported
Internal maintenance will be carried inside the plant. After that for external repair, MM will create subcontracting order for the spare. The receipt of the subcontracting order will result into the valuation type change from damage to repair and cost of repair will be loaded into the spare.
N
For internal maintenance, the spare will be repaired using internal spares and consumables. The cost of such repair will be settled to the maintenance cost centre.
8.4
Order Completion Confirmation
Fully system supported
After completion of maintenance activities for the spare, all the operations of the order need to be confirmed. Based on the valuation type, the spare valuation is modified from the damage to CONFIDENTIAL
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valuation type, the spare valuation is modified from the damage to repair and good receipt is made for the spare.
8.5
8.6
9.0
View Costs
Fully system supported
Technically and Business Completion
Fully system supported
Safety Order
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed. After confirmation for the maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.
N
N
When all the costs are settled and no further activities are pending against that order, business completion for the order is done. A Safety activity describes a notification meant for carrying out jobs related to safety requirements.
CONFIDENTIAL
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9.1
Notification by the user / maintenance in-charge of the equipment (M6)
Fully system supported
Process Description/remarks
Gap (Y/N)
User / maintenance in-charge creates a Notification for activities required for safety purpose for the equipment. N The location and other necessary data get copied into the notification from the equipment master. After receipt / creation of the notification, the maintenance planner creates the Maintenance Order (Order Type- PM06) using the screen of notification in change mode.
9.2
Create maintenance order from Notification
Fully system supported
The other way is to create order directly, describing the operations, requirement of material for the development activities in the order and Release the order.
N
If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.
9.3
Order Execution
Fully system supported
During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released CONFIDENTIAL
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reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.
After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully. 9.4
Order Completion Confirmation
Fully system supported
You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and suboperations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable CONFIDENTIAL
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issued material can be returned to stores from the order.
9.5
View Costs
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed.
N
9.6
Change / Complete Notification
Fully system supported
Notification will be closed after noting down all catalog & details of maintenance required to be recorded.
N
9.7
Technically and Business Completion
Fully system supported
After confirmation for the development maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile. When all the costs are settled and no further activities are pending against that order, business completion for the order is done.
CONFIDENTIAL
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Improvement / Modification / Redesign / Development/CAP EX
10.1
10.2
Mode
Fully system supported
Notification by the user / maintenance in-charge of the equipment (M5)
Fully system supported
Create maintenance order from Notification
Fully system supported
Process Description/remarks Improvements, Developments, Modifications or design changes are necessary part of maintenance to upkeep the equipment for higher productivity period, lower breakdown repair time etc.
Gap (Y/N)
N
These design change / modifications costs will be separated from other costs of maintenance using a separate order type.
User / maintenance in-charge creates a Notification for required design change / modification activities required for the equipment mentioning the purpose and results expected.
N
The location and other necessary data get copied into the notification from the equipment master. After receipt / creation of the notification, the maintenance planner creates the Maintenance Order (Order Type – PM05) using the screen of notification in change mode. The other way is to create order directly, describing the CONFIDENTIAL
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Gap (Y/N)
operations, requirement of material for the design change / modification activities in the order and Release the order. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.
10.3
Order Execution
Fully system supported
10.4
Order Completion Confirmation
Fully system supported
During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order. After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully. CONFIDENTIAL
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Process Name
Mode
Process Description/remarks
Gap (Y/N)
You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and suboperations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.
10.5
View Costs
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed.
N
10.6
Change / Complete Notification
Fully system supported
Notification will be closed after noting down all catalog & details of maintenance required to be recorded.
N
10.7
Technically and Business Completion
Fully system supported
After confirmation for the development maintenance order, the order needs to be technically completed and settled to the appropriate cost object based on settlement profile. The cost of CONFIDENTIAL
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appropriate cost object based on settlement profile. The cost of these types of orders can be settled to the fixed asset. When all the costs are settled and no further activities are pending against that order, business completion for the order is done.
11.0
11.1
Shut Down Maintenance
Create maintenance order
Fully system supported
Fully system supported
During plant shut down, maintenance department get good opportunity to do some maintenance work to upkeep the equipment for higher productivity period, lower breakdown repair time etc. Shutdown activities can be planned and scheduled in advance.
N
These shut down maintenance cost will be separated from other costs of maintenance using a separate order type. Shut Down Activities for the equipment are planned therefore it can be taken similar to preventive maintenance. As per the schedule, system will generate shutdown orders (PM07) for the equipments.
CONFIDENTIAL
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Mode
Process Description/remarks
Gap (Y/N)
The other way is to create order directly, describing the operations, requirement of material for the design change / modification activities in the order and Release the order. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used.
11.2
11.3
Shut Down Notification (M7)
Order Execution
Fully system supported
Fully system supported
System will creates a Notification for shutdown activities required for the equipment mentioning the purpose and results expected.
N
The location and other necessary data get copied into the notification from the equipment master.
During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by CONFIDENTIAL
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the MM. Upon receiving the material, it will be issued against the maintenance order.
After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully.
11.4
Order Completion Confirmation
Fully system supported
You use the remaining functions for the completion of an order, after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and suboperations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.
CONFIDENTIAL
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Process Description/remarks
Sl. No.
Process Name
Mode
11.5
View Costs
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed
N
11.6
Change / Complete Notification
Fully system supported
Notification will be closed after noting down all catalog & details of maintenance required to be recorded.
N
11.7
12.0
Technically and Business Completion
Fully system supported
Workshop Orders
Fully system supported
After confirmation for the development maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.
Gap (Y/N)
N
When all the costs are settled and no further activities are pending against that order, business completion for the order is done. The Workshop orders will be used for repair of spares/parts in the Central Workshop. The expenditure of such maintenance is recorded through Workshop Notification only. CONFIDENTIAL
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Process Name
12.1
Notification by the user / maintenance in-charge for the functional location (M9)
12.2
Create maintenance order from Notification (PM09)
Mode
Fully system supported
Fully system supported
Process Description/remarks
User / maintenance in-charge creates a Notification for required general maintenance activities required for the functional location mentioning the purpose.
Gap (Y/N)
N
The location and other necessary data get copied into the notification from the functional location master. After receipt / creation of the notification, the maintenance planner creates the Maintenance Order using the screen of notification in change mode. The other way is to create order directly, describing the operations, requirement of material for the general maintenance activities in the order and Release the order. If any operation requires External Services, then Steps as mentioned in 5.1 and 5.2 will also be used. CONFIDENTIAL
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12.3
12.4
Process Name
Mode
Process Description/remarks
Order Execution
Fully system supported
During maintenance of the machine (outside SAP), spares required will be mentioned in the order. Saving the order will create a reservation for the stock-able spares. Then Order to be released and against the Order Number or reservation number, material will be issued by the store. For non-stock spares, Purchase Requisition is created from the order. Based on the release strategy it can be released for procurement and Purchase Order will be created by the MM. Upon receiving the material, it will be issued against the maintenance order.
Order Completion Confirmation
Fully system supported
After completion of maintenance activities, the order needs to be confirmed. Order confirmation can be done partially or final. It is used to record how the work is progressing. For partial confirmation, order must not yet have been completed fully. You use the remaining functions for the completion of an order,
CONFIDENTIAL
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Gap (Y/N)
N
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Process Name
Mode
Process Description/remarks
Gap (Y/N)
after the order has been completed fully and a final completion entered. You enter time completion confirmations for operations and suboperations for maintenance and service orders to document the status of the processing for these operations. After that all the operations of the order needs to be confirmed. Extra stockable issued material can be returned to stores from the order.
12.5
View Costs
Fully system supported
12.6
Change / Complete Notification
Fully system supported
12.7
Technically and Business Completion
Fully system supported
The Planned vs. actual costs can be viewed after all issues and service entry sheets are completed. Notification will be closed after noting down all catalog & details of maintenance required to be recorded. After confirmation for the general maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile. When all the costs are settled and no further activities are pending
CONFIDENTIAL
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Process Name
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against that order, business completion for the order is done.
The Annual Maintenance Orders are special type of external services wherein contract for maintenance for equipment or functional location is given to external agency.
13.0
Annual Maintenance Orders
Fully system supported
Here the total responsibility to do preventive and breakdown maintenance shifts from the Plant Maintenance to External Body. Such type of maintenance and confirmation to the services for payment is done using the Service Purchase Order and Service entry sheet.
N
To track the cost of maintenance for any equipment, PM10 Annual Maintenance Contract will be used.
13.1
Fully Create Maintenance Order system (Type PM10) supported
Create a maintenance order for the equipment or a functional location using order type PM10. In the operation screen, mention the control key as PM03 as CONFIDENTIAL
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Gap (Y/N)
required in External Services. Using this key, the system requires the Service No. / Description, Quantity and price of the service. Based on the MM requirement for Purchase Requisition, certain fields are required to enter. On saving the order, the system creates the PR number for the external services. This PR number is used to create the Service PO by MM.
13.2
Confirming the External Services
Fully system supported
For confirmation of external services, Service Entry Sheet is used. The service entry sheet is created with reference to the Service PO. In the service entry sheet, the number or percentage of services is confirmed. Accordingly the data is updated in Controlling and Financial Accounting for releasing the payment for the external services.
N
In AMC services, the payment release (service entry sheet confirmation) can be carried in parts say quarterly release for payment. 13.3
Order Completion Confirmation
Fully system supported
Only after completion of the AMC services (exhausting the whole service order for AMC), the operation in the order is final confirmed and case the Final Confirmation, No remaining work, CONFIDENTIAL
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confirmed and case the Final Confirmation, No remaining work, clear open reservation ticks are made. In other case, order can be confirmed partially. In this case the Final Confirmation, No remaining work, clear open reservation tick is not made. The confirmation text can be written for comments.
13.4
14.0
Technically and Business Completion
Calibration Orders
Fully system supported
Fully system supported
After final confirmation for the AMC order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.
N
When all the costs are settled and no further activities are pending against that order, business completion for the order is done.
Special order that tests whether a specified piece of test equipment fulfills the performance criteria defined. For calibration, we need to define Characteristics and assigned it to the task list. CONFIDENTIAL
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Process Name
Mode
Process Description/remarks When the order is released, the system generates an inspection lot. The inspection lot appears in the work list for results recording in the Quality Management (QM) application component. You create a creation order if you want to check the accuracy of a piece of test equipment or a technical object. •
If you want to do this regularly (= planned), you use a maintenance plan, which regularly generates calibration orders.
If you do not want to do this regularly (= spontaneously), you create a calibration order directly. PrerequisiteThe equipment, for which you want to create a calibration order, must be created as a piece of test equipment. An inspection type for Plant Maintenance must be defined. This inspection type must be created for origin 14 (Plant Maintenance).
CONFIDENTIAL
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Sl. No.
Process Name
Mode
14.1
Create Calibration order
Fully system supported
14.2
Order Release
Fully system supported
After creating the order, for execution purpose the planner need to release the order.
N
14.3
Inspection Lot Generation
Fully system supported
When the order is released, the system generates an inspection lot. The inspection lot appears in the work list for the results recording in Quality Management.
N
Results Recording
Fully system supported
14.4
The maintenance planner creates the Maintenance Order (Order Type – PM08) manually or the system will generate it if it’s planned.
Gap (Y/N)
N
The results recording and usage decision for the test equipment are made using the functions in Quality Management. N As soon as you have made the usage decision, the system automatically executes follow-up actions, for example, status change of the test equipment ("Ready for use" -> "Not ready for CONFIDENTIAL
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Remarks
Will be done by QM
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use") or updating measurement readings.
14.5
14.6
15.0
Order Completion Confirmation
Technically and Business Completion
Spare Parts Planning
Fully system supported
Fully system supported
Fully system supported
After that all the operations of the order needs to be confirmed. Extra stock-able issued material can be returned back from the order. After confirmation for the general maintenance order, the order needs to be technically completed and settled to the appropriate cost centre based on settlement profile.
N
N
When all the costs are settled and no further activities are pending against that order, business completion for the order is done. In SAP, all the spares of equipment are formally structured as maintenance bill of material (BOM). The list contains the component number along with their quantity and unit of measure. The components mentioned in BOM can be stock-able or non CONFIDENTIAL
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stock-able. This becomes easy reference for the Spare Part Planning for carrying out maintenance activities.
During the creation of maintenance order, spares and consumables required for the maintenance of the equipment are mentioned in the order.
15.1
15.2
Order Release
Order Confirmation
Fully system supported
Fully system supported
For all stock-able materials, reservation is created in the system automatically. The reservation is available for the Store so that material can be issued against the reservation.
N
For all non stock-able materials, Purchase Requisition (PR) is created automatically following the release of the order and saving the order. After release of the PR based on release strategy, the material department creates the Purchase Order with reference to the PR and arranges the material for maintenance. There are many instances that the maintenance is left with the stock-able spares unconsumed. Such spares can be returned to store for future maintenance activities at the time of order completion confirmation. CONFIDENTIAL
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16.0
Process Name
Condition Monitoring
Mode
System supported
Process Description/remarks In SAP, condition monitoring can be done through measuring points. For that we need to create and assign measuring points and then on regular basis we need to take readings at those measuring points and post measuring document.
Gap (Y/N)
N
Once we capture all the reading then we can get the graph or take corrective action based on that. A physical or logical place at which a condition is described. Example can be Temperature inside a reactor, Speed of revolution of a wind wheel, the status is described using measurement readings, the operating duration of Diesel Generator etc. 16.1
Create Measuring Points for equipment
System supported
Measuring points are stored in the SAP System as master data for the Equipment. It can work as a counter to record the duration, based on manufacturer guidelines, the Preventive Maintenance Orders can be generated for the same. Counter are defined as Measuring Point in SAP and Counter readings are taken at counters at particular intervals and in CONFIDENTIAL
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Process Name
Mode
Process Description/remarks
Gap (Y/N)
particular measurement units. For example, counter readings for kilometers driven, operating hours or electricity used.
16.2
Create Measuring Document
System supported
The measurement document is the result of a measurement or counter reading being entered in the system.
N
16.3
Take necessary action (Maintenance Request)
System supported
If the reading is not in the range of accepted value then you need to take a corrective action by creating maintenance request and do the maintenance work.
N
CONFIDENTIAL
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Special Points: 1. All maintenance order costs will be settled at the cost centre level but development orders can be settled at fixed asset. 2. With MM discussion, there will have two valuation types for a spare: With value and zero value. The cost of damage spare will be taken as zero and cost of repair spare will be booked at the maintenance cost center. The maintenance cost of spare will be settled to the maintenance order and will not be loaded to the spare. 3. Name of person creating the maintenance notification and notification attended will be given in the two separate fields in (notification ‘reported By’ and ‘Technically Inspected By’) notification. 4. Permits will be used in SAP but at the time of release system will only give warning message if permit is not issued but error at the time of order completion. 5. Separate storage locations for maintenance (in workshop) can be defined for transferring low value components from stores. 6. Authorization for order creation & execution will be at shift engineer level but the order release will be at planning head (HOD) level. 7. For insurance claim, we can create a general notification type for capturing the information (if required).
CONFIDENTIAL
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Integration with Other Modules: MM 1. Valuation Classes will be defined for Electrical Spares/Mechanical Spares, Instrumentation Spares, Civil components and General Items (e.g. Engg. Consumables). Also valuation classes would be defined for Electrical Service, Mechanical Service, Civil Repairs and Instrumentation service. 2. MRP views to be maintained for critical spares (Insurance) and consumables. 3. Service Master to be maintained
FI/CO 1. Product-wise / department-wise cost center will be created, e.g., Hydrate Mechanical, Hydrate Electrical, Hydrate Instrumentation, Hydrate Civil; Alumina Mechanical, Alumina Electrical, Alumina Instrumentation, Alumina Civil; Utilities; Non-Plant etc. 2. G/L accounts will be created for all the different valuation classes mentioned above. 3. Cost-center-wise Budget allocation will be done.
CONFIDENTIAL
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List of Reports for Analysis 1. Detailed Breakdown Analysis-Equipment-wise/object part wise/Problem-wise/cause wise 2. MTTR and MTBF analysis for Equipments 3. Order type-wise cost analysis 4. Planner-group wise cost analysis 5. Equipment/Functional Location/Location/Plant wise cost Analysis 6. Report on usage of spares for Equipments 7. Report on service and Spares costs – Equipment-wise 8. Planned vs. Actual cost comparisons 9. Preventive Maintenance Schedule 10. Report on Preventive Maintenance Activities 11. Equipment History 12. Report on Measuring points/Measurement Documents 13. Report on Equipments having specific characteristics SPECIAL REQUIREMENT (ABAP) Ø For condition monitoring, requirement has come to us that the upload program for entering the DCS values to the SAP system (from xls) to be developed. Ø A report containing data of Consumption, Unrestricted stock, QI stock, Open PR quantities and open PO quantities for critical spares needs to be developed for the purpose of Spares Planning. CONFIDENTIAL
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Sl. Purpose No. Few Transaction for Reports
Description of Report
1
Technical Objects
2
Maintenance notification
32
Maintenance order
4
Completion confirmation Measuring Document
Structural Display-Equipment Structural Display- Functional Location Display notifications (Multi-Level) Notification List Display Tasks Display Notification Items Display activities Material Where-used List Display Orders Display Orders (Multi-Level) Display Operations Display Order and Operation List Display Component List Material Availability Confirmation List
IH03 IH01 IW29 IW30 IW67 IW69 IW65 IW13 IW39 IW40 IW49 IW49N IW3L IWBK IW47
Display Measurement Documents Maintenance Item List display
IK17 IP18
5 6
Remarks Transaction
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Purpose
Description of Report
Maintenance planning
Maintenance Plan List Scheduling overview list form MaintSchedule Date Monitoring Scheduling overview PMIS: Object Class Analysis PMIS: Manufacturer Analysis PMIS: Location Analysis PMIS: Planner Group Analysis PMIS: Object Damage Analysis PMIS: Obj.Statistic.Analysis PMIS: Breakdown Analysis PMIS: Cost Evaluation MTTR/MTBR Equipment MTTR/MTBR Functional Location
Evaluation of information system
Remarks IP16 IP24 IP30 IP19,IP24 MCI1 MCI2 MCI3 MCI4 MCI5 MCI6 MCI7 MCI8 MCJB MCJC
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SECTION IV
ANNEXURE – PROCESS FLOW CHARTS
CONFIDENTIAL
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Carry out Refurbishment activity( Outside SAP
PROCESS FOR HANDLING REFURBISHMENT ACTIVITIES
No
No
Spare identified for refurbishment
Is material or External Service required to carry out the job?
Yes
Create Refurbishment Order( Work Order
Allocate components services to Order
Carry out Refurbishment Activity Outside SAP
Is the spare rectified ?
No
Yes
Is the spare working satisfactorily?
Close the job
Keep the spare in stock for future use
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Issue Components Purchase Order
Yes
Create Service Entry sheet and accept
Technically complete the order
Settle the order
CONFIDENTIAL
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