02_sap pm plant maintenance universal process model

SAP – PM End User’s Training

Plant Maintenance Universal Process Model (UPM)

Plant Maintenance Universal Process Model (UPM)

Asset Management Structure

Asset Maintenance Management Conduct budget control Perform intercompany spare parts sales Measuring Point (PM & Fleet)

Project execution for assets Conduct order managed modifications Install capital equipment Dismantle equipment

Preventive / Predictive Maintenance Perform preventive / predictive maintenance

Corrective maintenance Conduct unplanned/emergency breakdown maintenance Perform low cost repairs Perform Planned Repairs Refurbish spare parts

Asset Management Processes

• Broken up into 4 Core Process Functions

– 1) Asset Maintenance Management

– 2) Execute Projects for assets

– 3) Preventive/Predictive Maintenance

– 4) Corrective Maintenance

Asset Management

Asset Maintenance Management

Project Execution For Assets

Preventive/ Predictive

Maintenance

Corrective Maintenance


• Conduct Budget Control – Depending on the implementation within the

company, budgetary control measures can be set up at cost center level or for the maintenance order itself. At individual maintenance order level, a budget can be set and once the budget has been reached, no more costs can be accumulated against that order. The budget can be changed with the necessary authorization

• Perform Intercompany Spare Parts Sales - – Within R/3, the stock of spare parts can be

viewed across plants. It is however, important to ensure that there is standardization relating to the relevant master data of the parts.

• Measuring Point (PM & Fleet) - – measurement documents are created against

the assets that allow for follow up activities in invoicing and managing fuel usage against distance incurred (Fleet)

Asset

Management


Project Execution For Assets


Maintenance


Conduct Budget Control

Perform Interco.

Spares Sales

Measuring Points

(PM & Fleet)

• Conduct Order Managed Modifications - – A modification to equipment is made to

improve its performance or to prolong its usable life. This is a planned intervention, for which a cost estimate and approval is required. This process adds value back to the asset.

• Install Capital Equipment - – Maintenance departments are commonly

used to assist with the installation of Capital Equipment. This process describes the use of the Maintenance Order to procure the equipment and the settle it to WBS elements and the settlement of the labor to expense cost elements.

• Dismantle Equipment - – Within Capital Projects, an expense portion

can exist in the dismantling or demolition of the equipment. This process make use of the Maintenance Order to accomplish. It also triggers the need for asset disposition and changes to functional location structures

Asset

Management

Asset

Management

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Conduct

Order Managed

Modifications

Install

Capital

Equipment

Dismantle

Capital

Equipment

Project Execution for Asset

Preventive/Predictive Maintenance

• Perform Preventive/Predictive Maintenance – Process allows for the development of

routine and repetitive pre-scheduled maintenance activities • Support Reliability Principles • Support Operational Excellence

Methodologies • Flexible for PM Optimization

activities • Flexible to institutionalize PMs based

upon COE Successful Practices • Options for Time Based, Performance

Based, and Condition Based PMs available

• Can be set to single cycle, multi-cycle, or a combination of both

• Can be used to manage EOSH routine activities

Asset

Management

Asset

Management

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Preventive/

Predictive

Maintenance


Processes support both Reactive and Proactive Corrective Maintenance activities:

Perform Emergency Repairs -

o In this process the steps before completion of the work are minimized so efforts go towards resolving

issues associated with the emergency. After completion of the repair, history is then gathered.

Perform Low Cost Repairs -

o In this process, a standing order is created to capture confirmed activities to repair minor stops and

short duration fixes.

Perform Planned Repairs -

o Newly created to enable and institutionalize the COE’s best practice Proactive Maintenance Planning

and Scheduling processes

Refurbish Spare Parts w/Split Valuation -

o This process deal with the refurbishment of - usually high value - faulty repairable spares. This is of

considerable economic importance for our bottlers and is often a core process in Plant Maintenance. It

is often much more cost-effective than a brand new purchase.

Reacti

ve

P

roacti

ve

Asset

Management

Asset

Management

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Perform

Emergency

Repairs

Perform

Low Cost

Repairs

Perform

Planned

Repairs

Refurbish

Spare Parts

Asset Management

• These 4 Core Process Functions, Asset Maintenance Management, Execute Projects,

Preventive/Predictive Maintenance, & Corrective Maintenance, now provides us the Asset

Visibility to:

1. Reduce Operating Cost by improving Labor utilization

2. Reduce Operating Cost by better managing parts and services

3. Reduce the Asset swell in spare parts by better management locally, regionally, and

globally, bring down unproductive inventory values

4. Reduce spend on spare parts procurement

5. Reduce the need to procure more capital

6. Focus on key Assets that provide the best opportunity to add availability and capacity

without adding capital

7. Increase Efficiency’s

8. Increase Throughput

9. Reduce other Supply Chain costs

10. Ultimately improve the Return on Assets involved in the Make Process of Finished

Goods

Asset

Management

Asset

Maintenance

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Plant Maintenance Technical & Object data & Base Requirements

Required Organizational Entities

10 10

According the Systems Applications and Products (SAP) standard organizational objects, the business scenario is mapped as follows:

General organization Location-based organization Planning-based organization

(i.e. oil & gas

company)


Company Codes

• Company codes generally represent the various legal entities within an organization. The Company Code is the lowest level for which you can produce a complete set of financial reports.

• There is no PM configuration in this area.

Plants

• In the Enterprise Resource Planning (ERP) System, the plant is a place of work or a branch within a company. The plant is integrated in the organizational structure as follows One plant (i.e. plant -0001) is assigned to exactly one company code (i.e. Company - 1000). One company

code can have several plants.

One plant can have several storage locations at which materials stocks are stored

Exactly one business area is assigned to a plant and a division

A maintenance plant can be defined as a planning plant

• A plant has the following attributes:

It has an address.

It has a language.

It belongs to a particular country.

It has its own material master data.

.

11 11


Maintenance plants and planning plants

• The maintenance plant of a technical object is the plant in which the object is installed.

• The planning plant of a technical object is the plant in which the maintenance tasks for that object are planned and prepared.

Planner groups is part of the planning plant which prepare a tasks for the technical object in maintenance plants

12 12

Required Organizational Entities Planner Groups

• Planner Groups are also organizational structure units. This is typically localized, but customization and logic to other functions such as notification screens and printing uses standard Planner Groups for PM to provide added functionality.

• The below have been set up in the system to be maintained .

• Planner groups can move to being plant specific because of segregation from CAM

Work Centers

• Work Center (Location Tab) is defined as an

organizational unit that assigns where the technical object is located.

• This is the Production Planner (PP) Work Center and not the Maintenance Work Center which is usually associated to labor.

• Where possible in Equipment Record and Functional Location Record this field should be populated. This require obtaining the PP Work Center information for populating this information in advance or as a dependency during load.

13 13


Storage Locations

• The Storage Location is defined as an organizational unit, allowing for differentiating between the various stocks of a material in a plant.

• Specified amounts of materials can be moved between different storage locations.

• A Storage Location is typically represented by a plant-unique 4-digit alpha-numeric.

• Material stocks can be differentiated, on a quantity basis, within one plant according to storage location.

• Storage locations are always created for a plant.

• Physical inventories are carried out at storage location level.

• For Coke One, common storage locations have been set up for each plant.

Plant Section

• Plant Section is generally considered a local

organizational unit. It is used to further breakdown a Maintenance Plant into physical or logical functions.

• Guidance is given in this area as the Plant Section is also used in the Functional Location structure to provide consistency in analysis of various plants in the BIG.

• There is no straight forward way to standardize this organizational unit as each plant has its own unique differences and configuration. The below provides guidance to selecting the Plant Section number.

010 – 019 General Plant Services, Building & Grounds

020 – 029 Bottle /Can Sorting & Delivery Systems

030 – 039 Blending & Mixing Production & Packaging

040 – 049 Production & Packaging

050 – 059 Warehousing and Logistics

060 – 069 Trade Services

070 – 079 Fleet

080 – 089 Office & Support Functions

090 – 099 Redeployable Asset

14 14

Required Data Elements - Functional Location • The structure indicator of a functional location determines the structure of the functional location label. It

establishes the following factors: Number of hierarchy levels of a technical system Key length of the levels Separators (hyphens)

• For Coke One, the Structure Indicator is ZSTD. The edit mask assigned to it is:

NNNN-NNN-NN-NNN-NNNNN

NNNN = Plant Code (i.e., 0000 = Singapore’s Plant Number) Spatial NNN = Plant Section (i.e., 010 = Manufacturing Bldg) Spatial and Process-based NN = Type of Line or Process (i.e., 01 = Production Area) Process-based NNN = Plant Line # or Plant Process# (i.e., 001 = Line 1) Spatial NNNNN = Equipment /System Function (i.e., 00100 = Filler) Functional

Example above = 0001-010-01-001-00100

15 15

Perform Preventive Predictive Maintenance - Master Data

SAP – Technical & Object data & base requirement

1. Work Center List Display (CR05)

2. Functional Location Structure Display (IH01)

3. Equipment List Display (IE03)

4. Function location master data Display (IL03)

5. Equipment master data Display


Asset Management


Conduct budget control

Perform intercompany spare parts sales

Measuring point (PM & Fleet)

Project execution for assets

Conduct order managed modifications

Install capital equipment

Dismantle equipment


Corrective maintenance Conduct emergency breakdown maintenance

Perform low cost repairs

Perform Planned Repairs

Refurbish spare parts

Asset

Management

Asset

Maintenance

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Conduct

Budget

Control

Perform

Interco.

Spares Sales

Measuring

Points

(PM & Fleet)

18

Measuring Points and Counters

A Measuring point is Master Data created for a Technical Object in order to document a Measurement or a Counter reading. This is done for one of three reasons:

You want to document the condition of a technical object at a particular point in time.

You want to perform Counter Based Maintenance (Preventive).

You want to perform Conditioned Based Maintenance (Predictive).

In the case of Counter Based Maintenance, maintenance activities are scheduled to be performed when the Counter of the Technical Object has reached a particular Counter Reading, for example, every 100 Operating Hours.

In the case of Condition Based Maintenance, maintenance activities are scheduled to be performed when the Measuring Point of a Technical Object has reached a particular state, for example, every time a brake pad has been worn away to the minimum thickness permitted, or when the cooling water for a Nuclear Power Plant exceeds the upper limit allowed.

The Measuring Point must have a Characteristic assigned to it.

18

Fleet Measuring Point (KM & Fuel Consumption reading)

Asset

Management

Measuring

Points

(PM & Fleet)

Create Equip

Create Measuring

Point Close

Asset

Maintenance

Management

Fleet Measuring Point (KM & Fuel Consumption reading)

SAP - Processing of Measurement Points process

flow

1. Display equipment master for vehicle w/ Measuring point (IE03)

2. Display & Changes measuring point list (IK32) i.e. 2000011

3. Reading entry (IK34)


Asset Management




Send fuel card information




Dismantle equipment






Asset

Management

Asset

Maintenance

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Conduct

Order Managed

Modifications

Install

Capital

Equipment

Dismantle

Capital

Equipment

Conduct Order Managed Modifications

Asset

Management

Project

Execution

For Assets

Order

Managed

Modifications

Request for project modificati

on

Finance Approval for WBS

Notification

approved

Create order & release

Confirmation

Close order &

Notification (TECO)

Finance settle to

WBS


A modification to equipment & function location is made to improve its

performance or to prolong its usable life. This is a planned intervention, for which a cost estimate and approval is

required. This process adds value back to the asset.


SAP - Order Managed Modifications process flow

1. Create Project request (IW21) 2. Create CapEx order & release (IW31) 3. Order Confirmation (IW41) 4. Close order & notification (TECO) (IW41) 5. Display WBS (CJ03)

6. WBS Expenses /Budget, Plan & Actual cost report (S_ALR_87013558)

Install Capital Equipment

Asset

Management

Project

Execution

For Assets

Install

Capital

Equipment


Maintenance departments are commonly used to assist with the installation of Capital Equipment. This process describes the use of the Maintenance Order to procure the equipment and the settle it to WBS elements and the settlement of the labor to expense cost elements. Request

for project installatio

n


Notification

approved


Confirmation

Close order &

Notification (TECO)

Finance settle to

WBS


SAP – Install Capital Equipment process flow

1. Install Capital Equipment (IE02)

Dismantle Equipment

Asset

Management

Project

Execution

For Assets

Dismantle

Equipment

Dismantle Equipment Within Capital Projects, an expense portion can exist in the dismantling

or demolition of the equipment. This process make use of the

Maintenance Order to accomplish. It also triggers the need for asset

disposition and changes to functional location structures

within R/3.

Request for

Dismantle


Notification

approved


Confirmation

Close order &

Notification (TECO)

Finance settle to

WBS

Dismantle Equipment

1. Dismantle Equipment Process (IE02)

SAP – Dismantle Equipment process flow


Maintenance Asset Management








Dismantle equipment






Asset

Management

Asset

Management

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Preventive/

Predictive

Maintenance

Perform Preventive/Predictive Maintenance

29

Preventive

Maintenance

Maintenance Plan

Schedule the Plan

Create PM Orders

Adjust planned

dates if required

Release the Order Execute Maintenance

Maint. Operation

Confirmation

Technically complete

the order

Record technical data

in notification

Complete notification

30 30

Strategy plan

Time-based Performance-based

Maintenance plans

Perform Preventive Predictive Maintenance

Preventive Maintenance Plan: Structure

Maintenance items

Preventive

maintenance plan

Maintenance

Schedule

Maintenance orders

Preventive

Maintenance

strategy

Maintenance

task list

Maintenance items

31

Maintenance

Package


SAP - Preventive maintenance process flow

1. Maintenance Strategy Display (IP12)

2. General Maintenance Task List Display (IA07)

3. Maintenance Plan Display (IP03)

4. Maintenance Plan Scheduling Display/Reschedule/Manual Call (IP10)

5. Generating and list of orders IP30&IW38


Asset Management








Dismantle equipment






Asset

Management

Asset

Management

Management

Project

Execution

For Assets

Preventive/

Predictive

Maintenance

Corrective

Maintenance

Perform

Emergency

Repairs

Perform

Low Cost

Repairs

Perform

Planned

Repairs

Refurbish

Spare Parts

Conduct Emergency Breakdown Maintenance

Asset

Management

Corrective

Maintenance

Emergency

Breakdown

Maintenance Break

down

Notification & Release

Work Order & Release

Confirm

TECO

Conduct Emergency Breakdown Maintenance

1. Create PM Notification- ZU (IW21)

SAP - Emergency Breakdown process flow

2. Create Order & Release (IW31)

3. Order Confirmation (IW41)

4. TECO (IW32)

37

Perform Low Cost Repairs

• Within a limited range, a technician may confirm times, and only times, to a standing order as long as there is no goods issue involved (no spare parts consumed).

• If a goods issue is involved or the time limit is exceeded, the technician has to trigger the release process for a notification and order.

• The work order is only open for a specified time period

• Notifications are created for low cost jobs and linked to the open work order

Asset

Management

Corrective

Maintenance

Perform

Low Cost

Repairs

• Create Standing Work Order (ZP)

• Create Notifications (ZU)

• Assign Notifications to Standing Work Order

• Confirm Notifications

•

Standing Order

Low Effort Not.

Assign

Not. To

Order

Confirm

Close

Order



Low Cost Repairs – Process flow

2. Create PM Notification (Low cost assign to order) (IW21)

1. Create Order & Release – Open order, ZP03(IW31)

3. Operation Confirmation (IW41)

5. TECO (After 6M or 1Y) (IW32)

4. Notification close – (after job is done) (IW32)

Perform Planned Repairs Process Flow

Asset

Management

Corrective

Maintenance

Perform

Planned

Repairs Problem

ID’d

Notify

Create

WO

Plan

WO

Schedule

WO

Execute WO

Doc & Close


SAP - Planned Repairs process flow

1. Create PM Notification- ZP - (IW21)

2. Create Order & Release (IW31)


4. TECO – Order & Notification close (IW32)

Refurbish Spare Parts

Bought stock and

put into spares

Special type of

maintenance

order

Broken Item

Broken Item

Asset

Management

Corrective

Maintenance

Refurbish

Spare

Parts

• High value materials or spare parts, such as motors, are often used in production systems. In the event of failure or damage to these types of parts, they may be replaced by a functioning spare, then refurbished in the maintenance department or externally if deemed more cost effective to do so. Refurbishment is frequently considered more cost effective and should be applied when this is the case. The cost to process the routine has to be weighed also, considering planner time, purchaser time, and storeroom attendant time. With this in mind, as a guideline, spare parts having an individual value of 500 Euros or more (roughly $750) should only be considered for refurbishment. Only in special cases should other parts be put into the refurbishment process.

• In typical corrective maintenance repair processes, some described above, work order are set for the consumption of materials or parts. In the refurbishment process, work orders are intended to repair the defective part. To accomplish this, the refurbishable material has to be classified by 3 different states, called valuation types. They are: New, Refurbished, and Defective. The valuation types have been set up in the system as:

•


Asset

Management

Corrective

Maintenance

Refurbish

Spare

Parts



SAP - Refurbishment of spare parts process flow

1. Create Order & Release – (IW81)


3. TECO – Order close (IW32)

Material Masters

• The material master contains descriptions of the articles and parts that the plant, manufactures, and

stores. The material master is the central source for calling up material specific information within the plant. Since all the material data is integrated in one master record, the problem of data redundancy is minimized. This integration also enables the stored data to be used jointly by purchasing and other areas such as Inventory Management, Material Request Planning (MRP), and Accounts Payable.

• Plant Maintenance uses the following Material Types.

ZDIE SCALE Services

ZENS PM Spares Non Standardized Local

ZESS PM Spares Standardized Global

ZIMA Maintenance Assemblies

ZNFA Fixed Assets

ZNNM Non-Stock Materials

ZNVM Non Valuated Material

45 45

Material Masters

SAP – Stock Item process flow

1. Materials List Display (MMBE)

2. P.R. List Display (MN53N)

3. P.O. List Display (ME23N)

Order - with Stock Item material

Released Planned Wos

(ZP01, ZP03, etc)

Work Order

0010 Check pump

0020 Renew seals Material

Issue/ Pick Lists

Problem

ID’d

Create Notificatio

n & Release

Create order (+ Materials) &

released

Received materials

Confirm order

TECO & Close Order

Material

SAP – Stock Item process flow

1. Create Notification & Release (IW21)

3. Goods Receive Process (MIGO) 4. Confirm order (IW41)

5. TECO and close order (IW32)

2. Create order, Add material & Release order (IW32)

Order - with Non-Stock Item Material

Released Planned Wos

(ZP01, ZP03, etc)

Work Order

0010 Check pump

0020 Renew seals Material

Issue/ Pick Lists

Problem

Create Notificati

on & Release

Create order (+ Materials) & released

PR Created Automatically

Received materials

Confirm order

TECO & Close Order

Material

SAP – Non-Stock item maintenance process flow

1. Create Notification & Release (IW21)

3. PR Created automatically 4. Good Receive (MIGO)

5. Confirm order (IW41)

2. Create order, Add material & Release order (IW32)

6. TECO and close order (IW32)

02_sap pm plant maintenance universal process model

Documents

asset disposition

capital projects

stock of spare parts

core process functions

expense cost elements

cost estimate

low cost repairs

cost center level