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SAP ERP 6.0 Enhancement Package 2

Ramp-Up Knowledge Transfer

Maintenance Event Builder-Business Description-

Benefits

Maintenance Planning & Scheduling

Planning Using Maintenance Event Builder

Appendix

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Planning and Scheduling Defined

PlanningDefining resources needed to perform a maintenance task and sequence in which they are performed is known as Maintenance Planning.Planning is performed so that task when started can be finished within shortest possible time, at lowest cost and at highest safety standards.

SchedulingThe Assignment of many planned jobs within a defined period such that it utilizes the resource in best possible way and kept within known constraints.

DispatchingThe assignment of Resources to execute a scheduled task to ensure best utilization of resource on the day of execution

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Process Flow for Maintenance Planning

Work Identification

Raise Notification

Work Evaluation & Estimation

Planning & Scheduling

Execution Planning

Dispatching task

Execution & Recording

Planned WorkReady to be Scheduled

Unplanned Work

New Incoming work(CM + PM)

Weekly Schedules Daily Schedules

Weekly Bucket Daily Bucket

• Maintenance Planner receives backlog items as open notifications or orders• Based on priority and resource availability planner does rough cut planning• Based on schedule from operation / production team synchronize weekly plans• Planner monitors daily progress and plans work for next planning bucket

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Simplified Maintenance Planning

Maintenance Event Builder (MEB): A Workbench for the Maintenance Planner• It facilitate Maintenance Planning and Scheduling• It helps in elimination of redundant tasks within a work package• It sequences maintenance tasks by assigning them to an appropriate time frame• Maintenance Event Builder allows planning of Simple or Project based maintenance events

t

Prod. Line / Asset 1Prod. Line / Asset 2Prod. Line / Asset 3Prod. Line / Asset 4

ScheduledMaintenanceScheduled

Maintenance

UpgradesUpgrades

DeferredWork

DeferredWork

MaintenanceRequirements

General Task ListsGeneral Task Lists Standard Network / WBSStandard Network / WBS

Notifications

Maintenance Event Builder

OrdersProject

Revisions

Maintenance Opportunities / Events

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Benefits



Appendix

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Planning Process with Maintenance Event Builder

Planner Reviews all open maintenance request that needs actionsPlanner groups these task based on priority, location, resources needed

Review maintenance backlog

Review maintenance Opportunities / Events

Create work package for an maintenance event

Generate orders for an maintenance event

Elimination of redundant orders within a package

Sequence the orders

Planner reviews opportunities to perform maintenance with operations teamPlanner enters these opportunities as revisions in Maintenance Event builder

Based on the dates of maintenance event and priority of the maintenance requests, the planner assigns maintenance requests to a Maintenance Event

Once the work load is evaluated by operations and maintenance team, the planner generates orders or assigns generated orders to work package

Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical objects are deleted

Based on the assigned logic, Maintenance Event Builder proposes an optimized sequence for the orders. Planner can manually adopt the proposed sequence

Check for Capacity Utilization

Planner ensures that the capacity required to execute the planned job is available with appropriate buffers so that uninterrupted execution can be achieved

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Seven Step Process for Maintenance Planning and Scheduling using Maintenance Event Builder

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Step 1 : Review Maintenance backlog

Planner Reviews all open maintenance request that needs actionsPlanner groups these task based on priority, location, resources needed1

MEB Allows review of maintenance requests that needs planning with flexible Selection Criteria

Technical ObjectPriority…

Planner can also view all the maintenance requests that are already assigned to a maintenance opportunity (revision)

Flexible display of selected maintenance request by appropriate

GroupingSortingFiltering

Easy status tracking and prioritization based on icons

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Step 2: Review Maintenance Opportunity / Event

Planner meets with operations team to plan appropriate maintenance eventPlanner enters these opportunities as revisions in Maintenance Event builderMEB Allows review of all major

maintenance events (Revision) planned by planner based on following criteria

Technical ObjectDate rangeType of Event…

MEB allows assignment of Projects to a Revision

Flexible display of selected Revision

GroupingSortingFiltering

Each revision can be further classified with status management and tracked change documents

Revision can be created manually or with operational planning system using API

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Based on the dates of maintenance event and priority planner assigns maintenance requirements ( notification or WO) to a Maintenance Event

Step 3: Create a Work Package for an Event

Planner can be responsible for large number of distributed assets. Planning board allows visualization of all the events planned for these assets.

Planner can select work package for an event from planning board or using flexible selection criteria.

Selecting backlog for the relevant asset and time period planner can prepare package of work that can be schedule together and optimize utilization of resources and opportunity for doing maintenance.

Planner can include task by simple drag and drop functionality and create simulative orders to review total capacity needed

Planner can also include order created by supervisor by assigning the linked notification to the event

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Once work load is evaluated by operations and maintenance team planner generates orders or assigned generated orders to the work package

Step 4: Generate Orders for a Maintenance Event Maintenance Event Builder can create orders for all the notifications assigned to a work package by a single click

If the orders already exists for a notification, these orders also gets assigned to the same revision

Once the orders are created using MEB they have a special system status “MEB”indicating that they were created using MEB

If the notification is assigned with Hierarchical task list, than MEB creates orders based on configuration of the technical object, and valid task lists from HTL. Valid task lists are used to create individual orders, While creating Orders appropriate work centers based on plant (ref. appendix)

If notifications are de-assigned from an event for any reason, all the corresponding orders are marked as deleted

Order creation can be planned using background job for large events that may have thousands of orders

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Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical objects are deleted

Step 5: Elimination of Redundant Orders in a Package

One of the most important advantage of using Maintenance Event Builder is to create an optimized work package

Quite often the maintenance planner plans preventive maintenance, inspection as well as break down maintenance for an asset in the same event. Each of these tasks have many operations that are common and do not need to be performed twice. (e.g. Opening and closing of the equipments, Lock Out and Tag Outs, Inspections and Testing). If appropriate Hierarchical task lists are maintained by the planner, Maintenance Event Builder can eliminate these duplicates and propose the most optimum package (ref. appendix)

Maintenance Event Builder checks for the duplicate tasks by using task list type, group name and counter

If required, logic for elimination can be enhanced using appropriate BADI

Notification

Chk1

T2

T1

ST1

ST2

ST3

ST4

ST5

ST6

SB1

ST1

ST7

ST3

OrderST1

OrderST3

Elimination

Revision

OrderST1

OrderST2

OrderST3

OrderST4

OrderST5

OrderST6

OrderST7

This step works only when HTL is used and is an optional functionality

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Step 6: Sequencing and Scheduling the OrdersOnce a list of orders are created and approved, it is important to sequence them properly, specifically if there are large number of orders

To ensure orders are sequenced appropriately, they are assigned to project network or WBS. Dates of orders are synchronized with Project network or WBS

Networks is used to prepare rough cut plans so that planner can forecast estimated resource requirements

Once the maintenance orders are created and confirmed are assigned to network activities to based on “PM/PS reference elements” maintained in orders and Activities (ref. appendix)

Orders can be also assigned manually using drag and drop type of user interface

Once the orders are assigned, orders can be scheduled along with the network

Based on the assigned logic, Maintenance Event Builder proposes an optimized sequence for the orders. Planner can manually adopt the proposed sequence

PM/PS Ref. Elem.

PM/PS Ref. Elem. PM/PS Ref. Elem.

PM/PS Ref. Elem.

This step works only when Project oriented maintenance is used. MEB can be used without Project System

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Planner ensure that capacity required to execute the planned job is available with appropriate buffers so that uninterrupted execution can be achieved

Step 7: Evaluate Capacity Utilization

Once the order and network are scheduled, the planner can easily review utilization of various capacity of work centers used

The Planning board can provide a graphical view for a given planning horizon of each capacity

If required the planner can get additional orders in the events or defer some orders. The Planner may decide to get some external resources if there are high priority jobs that require completion in a given time period

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Benefits



Appendix

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Benefits and Prerequisite

BenefitsMaintenance Event Builder allows integrated planning of major as well as minor maintenance events

MEB allows most of the planning and scheduling steps to occur within a single transaction

MEB allows forward planning to ensure high utilization of available maintenance period reducing the need of multiple shutdown for the same technical object

MEB allows integration of maintenance orders with project activities and manage preventive maintenance, modifications and upgrades

Integration of Project system and Sales within ERP, allows streamlined processes for execution of third party maintenance work

Prerequisite

Prerequisite of activating the Business Function LOG_EAM_POM ( Enhancement Package 2 – Project Oriented Maintenance) are the installation of all relevant support packages of an ECC-DIMP system. Since technically the new features coming with this business function are belonging to the ECC-DIMP component this steps are essential

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Benefits



Appendix

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Application of Hierarchical Task ListBenefits

Maintenance Planning & SchedulingHierarchical Task list to organize tasks

SAP ERP 6.0 Enhancement Package 2

Ramp-Up Knowledge Transfer

Hierarchical Task List

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Planning and Scheduling Defined

PlanningDefining resources needed to perform a maintenance task and sequence in which they are performed is known as Maintenance Planning.Planning is performed so that task when started can be finished within shortest possible time, at lowest cost and at highest safety standards.

SchedulingThe Assignment of many planned job within a defined period such that it utilizes the resource in best possible way and kept within known constraints.

DispatchingThe assignment of Resources to execute a scheduled task to ensure best utilization of resource on the day of execution

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Task list for Maintenance Management

Task list allows maintenance planner to continuously improve andlearn good maintenance procedures. Planner can make them key part of planning and scheduling of maintenance procedure.

Maintenance Planner creates task list with assistance of trainedtechnical staff within the organization, learn from the experience while jobs are getting executed or with help from OEM responsible for design and construction the asset.

If maintenance is performed once, one can fairly assume that it would be required again. Task list helps in making libraries of jobs that can reused.

Within SAP EAM solution; task list forms basis for calculating cost of performing a task, optimized scheduling of a maintenance taskand also forms the basis on which improvements in maintenance execution can be achieved

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Maintenance Management and Task List

Work Identification

Raise Notification

Work Evaluation & Estimation

Planning & Scheduling

Execution Planning

Dispatching task

Execution & Recording

Planned WorkReady to be Scheduled

Unplanned Work

New Incoming work(CM + PM)

Weekly Schedules Daily Schedules

Weekly Bucket Daily BucketTask list simplifies the

process of planning and improves planning

accuracy

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Organization of Standard Task List

Task ListHeader

Components

Operation

Tools

Documents

Operation

Task List Header• Task list header stores description,

Assignment to serviceable Item, Planner group, Status and Main Maintenance Work Center

• Each task list can have multiple operation that required to accomplish a maintenance task

Task List Operation• Task list operation defines how much time is

required to perform each steps and what type of resource is required to perform required step

• Material, Tools and Documents required to perform maintenance step are also linked to operation

Limitations of Standard Task list• A reasonable size of maintenance requires large number of operation and makes task

list quite difficult to maintain • If one task list contains all the operations, same set of operations gets repeated in

multiple task lists having similar requirements• If one task list contains multiple trades (work Center) and supervisors for different

trades are different, coordination of order becomes difficult

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Organization of Hierarchical Task List

Task List Hierarchy• Task list hierarchy allows grouping

of set of task list together• Hierarchy node itself does not

have any operations that can be performed

• Hierarchy consist of executable task lists at the lower level

• Each executable task list creates orders when a hierarchical task list is used in a maintenance notification or a maintenance plan

Task List Hierarchy

Task List

Task List Hierarchy

Task List Hierarchy

Task List

Task ListHierarchy

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Hierarchical Task list to Organize maintenance Work

With the Hierarchical task list, the planner can organize a complex work into small identifiable tasks The hierarchical structure allows selection of tasks from any level and all the subordinate task list are considered as a group when orders are createdCost and Scheduling can be managed easilyPossibilities to optimize the work package by removing duplicate tasks (When used with Maintenance Event Builder, MEB) allows a flexible and technically correct hierarchical structure of task listVariant configuration allows usage of same hierarchical task list for multiple different type of assets for different type of requirementsEnhancements to adopt and add more attributes allows efficient and easy search criteria

Main Task

Task by Mechanic (M0)

Task by Electrician (E0)

Task by Carpenter (C0)Mas

ter D

ata

Sub taskHierarchical task list is a new representation of task list. It allows organizingtask lists in a hierarchythat links set of work steps together.

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Defining Centralized Task List

Electricians

Mechanics

Carpenters

E3E1 E2 E4

M3M1 M2 M4

C3C1 C2 C4

Plant-1 Plant-2 Plant-3 Plant-4

The Hierarchical Task List allows the definition of cross plant Task List. When Hierarchical Task Lists are used, actual work centres in work order are adopted based on selected plant

Main Task

Task by Mechanic (M0)

Task by Electrician (E0)

Task by Carpenter (C0)Mas

ter D

ata

Sub task

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Usage of centralized task list in PM/CS order

The work center used in the order is based on a conversion table maintained using MEBOR transaction

In the example shown here

Centralized Task list has been created with work center ABCD Plant 1000

When the Order is created –

For Plant 2000WC in operation AAAA

For Plant 3000WC in Operation BBBB

Another important factor in task list to have central maintenance of Task list

You can use central task lists for PM/CS orders when your maintenance work is performed in varying maintenance locations but the maintenance work to be performed itself does not change. A task list for the particular maintenance work in question needs to be present in the system only once for planning purposes. At the time the maintenance work arises, the system replaces certain information in the central task list with maintenance location and plant-specific information. Furthermore, when you notify the system of a change of location of maintenance work, the system can subsequently delete an already existing maintenance order for this location and create a new order with an updated maintenance task list for the new maintenance location.

When you use central task lists for maintenance activities, you need to specify certain plant-specific data. When the system creates a PM/CS order with reference to a central task list, or when you change the maintenance location in an existing PM/CS order and re-explode the central task list, plant and work center-specific information is replaced depending on the maintenance location specified in the order as shown in the diagram below. The conversion is based on the rule that the main work center of the PM/CS order header determines the result of the task list explosion

The conversion only works if the planning plant of the PM/CS order is the same as in the central task list referenced by the order.

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Task List Hierarchy

Task List

Task List Hierarchy(sub-Node)

Task List Hierarchy(Sub Node)

Task List

Task ListHierarchy

Operation 1

Operation 2

Material

Tools/Docs

Operation 3

Work Order

Operation 1

Operation 2

Material

Tools/Docs

Operation 3

Task List Hierarchy

Maintenance Notification

Task List Hierarchy

Maintenance Order

The Task List Hierarchy can be used to create orders directly

• Task can be linked to notification and when the order is created directly, system explodes the HTL & creates an order with operations from the underlying task lists

• Task list can be included while creating an order. System will explode the HTL and include operations from all underlying task lists

Orders created with HTL will have operations from all subordinate task list.

While exploding the task list, work centers are changed based on the plant

Material and tools are linked to operations

Using Hierarchical Task List to Create Order

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Task List 1

Task List Hierarchy(HTL 11 )

Task List Hierarchy(HTL 12)

Task List 2

Task ListHierarchy

Work Order

Task List 1

Task list 2

Task List3





Task List 1

Task List 3

Task ListHierarchy

Create Order using Maintenance Event Builder and HTL

Work Order

Work Order

Task List Hierarchy can be used to create orders using Maintenance Event Builder (MEB)

• Hierarchical Task can be linked to notifications

• The Maintenance Event Builder allows the creation of a work package for a set of notification

• The MEB creates orders for each underlying task list attached to HTL used in notification

• If an underlying task lists appears more than one time, MEB creates orders only once and avoids duplicate tasks

In the above example three orders are created for two notifications because “Task List 1”is appearing twice in the package

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Benefits, Limitations and Prerequisite

BenefitsThe Hierarchical Task List allows to organize a maintenance package in a clear package of steps

The Hierarchical Task List allows the creation of master data centrally for multiple plants

The Hierarchical Task List simplifies the implementation of variant configuration and allows the usage of a Task List for a large number of similar equipments / assets

LimitationCurrently the Hierarchical Task List can not be used with Maintenance Cost Budgeting. As a work around, the maintenance plans that uses HTL, needs to be separately exploded and used with task list scenario in MCB

Prerequisite

Prerequisite of activating the Business Function LOG_EAM_POM ( Enhancement Package 2 – Project Oriented Maintenance) are the installation of all relevant support packages of an ECC-DIMP system. Since technically the new features coming with this business function are belonging to the ECC-DIMP component this steps are essential

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