“FUTURE”SAP Implementation

Design Phase– Plant Maintenance: Preventive Maintenance : Time Based Maintenance

, February, 04th 2012Misurata

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Preventive Maintenance Types

They are basically three types of preventive maintenance:

Time based: The preventive maintenance task is triggered when a certain time limit is reached (for example, every six months).

Performance-based: the preventive maintenance task is triggered when a certain performance level is reached (for example, every 10,000 kilometers, every 1000 working hours).

Condition-based: The preventive maintenance task is triggered when a certain diagnostic value has not been reached or has been exceeded (for example, a pressure status lower than 15 bar or a temperature higher than 85°).

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Maintenance Task List

Types of Maintenance task list:

Maintenance task list for Equipment.

General maintenance task list.

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Maintenance Task List

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Maintenance Task List

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Maintenance Task List

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Types of Maintenance Plan

There are three types of Maintenance Plans:

Single cycle plans: The same maintenance activities in full at regular intervals (time based or performance based). Maintenance task list is not a must.

Maintenance strategies and strategy plans: The maintenance activities are based on each other or supersede each other, either as a time based strategy (ex: every 3/6/12 months and so on) or as performance based strategy (ex: every 10,000 / 20,000 / 40,000 km and so on): a maintenance task list is a must.

Multiple counter plan: The fixing of the maintenance date depends on several influencing factors (ex: every six months, every 10,000 km, every 1,000 operation hours ). Maintenance task list is a must.

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Preventive Maintenance Time Based: Single Cycle

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Preventive Maintenance Time Based: Single Cycle

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Preventive Maintenance Time Based: Single Cycle

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Preventive Maintenance Time Based: Single Cycle

Scheduling Parameters:

Scheduling indicator is used to lay the basis for calculating the planned dates:

Time: The calculation basis for the month is always 30 days; all calendar days are counted. Example: Cycle 3 MON, start of cycle April 01 results in a plan date of June 30.

Time key date: The calculation basis is the effective days of a month. Example: Cycle 3 MON, start of cycle April 01 results in a plan date of July 01: is not used for single cycle plan.

Time factory calendar: The calculation basis for the month is always 30 days; only the factory calendar days are counted. Example: cycle 3 MON, factory calendar Saturday/ Sunday /public holiday free, start of cycle April 01 results in a plan around August 10 (depending on when the public holidays fall )

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Preventive Maintenance Time Based: Single Cycle

Scheduling period: To create a preview of the pending maintenance dates. The scheduling period gives the period of the preview in days, months, or yearsSet the scheduling period to 365 days to have a preview of the entire year for a maintenance plan.

Call horizon: Call horizon is used to specify in percentage when an order should be created for a calculated maintenance date; in other words, how much time is to elapse between two planned dates until the order is created in the system (The date as of which the order can then be created is known as the maintenance call date).

Ex: cycle 6 MON (180 days): planned date and completion date of the preceeding order April 01.

Call horizon : 0%: order can be created immediately if the preceding order has been completed, that is, maintenance call date April 01.

Call horizon: 100%: order can be called once the next planned date has been reached, that is, maintenance call date September 28.

Call horizon: 90%: order can be called when 90% of the time between April 01 and September 28 has elapsed, that is, maintenance call date September 10.

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Preventive Maintenance Time Based: Single Cycle

Schedule Maintenance Plan: In practise a program running in background ensures that the maintenance call orders are created on the correspondant date based on the scheduling parameters defined in the Maintenance Plan.

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Preventive Maintenance Time Based: Single Cycle

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Preventive Maintenance Time Based: Single Cycle

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Preventive Maintenance Time Based: Single Cycle

PM order generated from Maintenance Plan

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Ord

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para

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Reservation or Purchase Requisition

Pre

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execu

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Shop paper

Goods Issue of spare parts

Order Release: immediately when order is created or manually.

Time confirmation

Main

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Execu

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C

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Clo

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Execution

1.Technical close.2.Ordre Settlement (Controlling /Batch job)3.Business Completion (Batch job).

Minutes

CRP+Scheduling

Preventive Maintenance Time Based: Cycle Plan

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Preventive Maintenance Time Based: Single Cycle

Capacity Overview:

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Preventive Maintenance Time Based: Single Cycle

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Preventive Maintenance Time Based: Strategy Plan

Create Maintenance Strategy:

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Preventive Maintenance Time Based: Strategy Plan

Create Maintenance Strategy:

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Preventive Maintenance Time Based: Strategy Plan

Create Maintenance Task List for Strategy Plan:

It is a must to include a maintenance task list with the same strategy as the maintenance plan.

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Preventive Maintenance Time Based: Strategy PlanCreate Maintenance Task List for Strategy Plan:

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Preventive Maintenance Time Based: Strategy PlanCreate Maintenance Strategy Plan:

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Preventive Maintenance Time Based: Strategy PlanCreate Maintenance Strategy Plan:

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Preventive Maintenance Time Based: Strategy Plan

Starting the strategy Plan: When you start a strategy plan, you must decide whether::

This is a restart (for example, if a new machine is purchased).

or start in the current cycle (for example, existing machine with maintenance dates already implemented): In Go live as no data is stored in the system yet.

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Preventive Maintenance Time Based: Strategy Plan

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Preventive Maintenance Time Based: Strategy Plan

Order generated from Maintenance Plan

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Preventive Maintenance Time Based: Strategy Plan

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Ord

er

Pre

para

tion

Reservation or Purchase Requisition

Pre

para

tion

of

execu

tion

Shop paper

Goods Issue of spare parts

Order Release: immediately when order is created or manually.

Time confirmation

Main

ten

an

ce

Execu

tion

C

om

ple

tion

Clo

se &

S

ett

lem

en

t

Execution

1.Technical close.2.Ordre Settlement (Controlling /Batch job)3.Business Completion (Batch job).

Minutes

CRP+Scheduling

Preventive Maintenance Time Based: Cycle Plan

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PM Workshops

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