jk_bbp_pm_bp_0500

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Project Name

Title

JK Cement

Breakdown Maintenance

Version

Document ID

1.0s

JK_BBP_PM_BP_0500_V1.0

Author Akhilesh Kumar Singh

Reviewed By XXXXXXX XXXXX

Date 01.11.2012

T r a n s f o r m i n g E n t e r p r i s e s

Consulting

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Business Blue Print- Business Process- PlantMaintenance

File Name: Release: ECC 6.0

Responsibility: PM Status: Closed

Copyright © 2011 JKT Page 2 of 9

IMPLEMENTATION_BLUE PRINT

Business Process Details

ModulePlant Maintenance

Process Breakdown Maintenance Sub Process /No

Breakdown Maintenance & Civil Maintenance JK_BBP_PM_BP_050

0

Description Breakdown Maintenance & Civil Maintenance

Sr No Business Process Explanation

1.1 As Is Process General Explanation

1.2 Explanation of Proposed Process

In case of any Break down, Production User/CCR/Maintenance Engrr.generates a Maintenance Notification of Notification type M2. He records theBreak down occurrence time, technical object (Equipment/ Function location)affected, & damage or any kind of observation found. Online information ofBreak down & status of technical object will be available to all.

The maintenance team (Electrical/ Mechanical/Instrumentation) attends thebreak down and records the malfunction end time, causes & activitiesperformed while attending the break down. Here he can also add tasks ifrequired to be performed afterwards, if some temporary arrangements havebeen done.

He creates a maintenance order of Order type PM01 to issue materials/spareparts if required from their local stores. If the material is not available in theirstore a purchase requisition can be made directly from the maintenance order.In operation list of the maintenance order all operation performed, work center

used and man power hour utilization is recorded.

Break down indicator in notification, will be marked if break down occurs.External services can also be utilized from maintenance orderSpare parts planning can be done using Bill of materials.

Actual/planned/estimated cost incurred on attending break down will besummarized with labor & spares cost separately.

Failure analysis can be recorded.

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Refer flowcharts below:1. General Maintenance process (Internal processing)2. General Maintenance process (External processing both Material &Service)

o

PROCESS FLOW CHARTS1.1.1 General Maintenance Process (Internal processing)

Create Notification(Request for maintenanceby plant user/CCR)

-Description of job-Required Start andEnd times of job

-Technical object no.

-Technical findings-Object part, damageetc. (optional)

-Tasks to perform

Notificationreceipt byMaintenance Dept.

Inspection ofMachine at site bymaint. person

-Enter additional technical

findings and tasks in theNotification.-Release the Notification(Put in process)

Create Maintenance order for the notification(by Maintenance planner)

-Description of order-Technical object details

(transferred from Notification)-Assign Maintenance work

center (transfers automaticallyfrom the technical objectmaster record)

-Plan operations in the orderwith number of personsrequired and work times.

-Plan spare materials with

required quantities-Assign responsible person

X Y

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Schedule the order(for planned start and end timesdepending upon the availability of

manpower at the Maint. Work center)

Issue s are materials from stores

Execute plannedmaintenance work at site

Completion (time) confirmation(of Maintenance order operations)

Release the order

Y

Inspection of completedwork at site by authorizedperson

Technical CompletionOf Maintenance order(by authorized person)

Settlementof Maintenance order

(by authorized person)

Business completionof Maintenance order

(by authorized person )

Order closed

-Complete the technicalFindings in Notification.

-Complete the tasks

Notification Completion

(by authorized person)

X

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1.1.2 Maintenance order (External processing)

Create Maintenance order

-Description of order-Technical object details-Plan external service operationinthe order. Enter operation

details-Service description or selectservice from the standard servicecatalog, service quantity & unit,price and vendor (optional).

Schedule the order

1.For Non Stock Materialpurchase requisition is made2.Purchase Order iscreated.

Execute internal processingwork at site, if any

Release the order

Purchase requisition for theexternal service is createdautomatically.

Purchase requisitionreceipt by Purchase Dept.

Create Purchase order

Execution of requestedexternal service by vendor

Create Service Entr sheet

Y

X

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Notification Processing

Transaction code for creating Maintenance Notification is: IW21Menu path is : Logistics Plant Maintenance Maintenance ProcessingNotification CreateNotification type for are: M2: Malfunction Report

1. Identification of Malfunction by Operation or Maintenance department.2. A Maintenance Notification is created with type M2 in the system depending on

requirement.3. Specifying the Description of the Notification as per the nature of maintenance

request or malfunction.4. Mentioning Object Number and time of request with requisitioner identification in

to the notification screen.5. The initiator of Notification can enter the Technical findings (Object part, Damage

or cause of damage etc) if he knows the details.6. Saves the notification.7. After the job is completed the production person will put the timing of malfunction

end and his identification. 8. Maintenance person has to complete any task assigned to notification and enters

the activities.9. Lastly, the notification has to be completed by the authorized person.

Completion (time) confirmation

(of Maintenance order operations)

Settlement

Business com letion

Confirm/Accept Services(By entering exact quantityof received services in theService Entry sheet by anauthorized person)

Technical Completion

Invoice receipt

Bill payment

Cost

Y

X

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Order Processing

The transaction code for creating order is IW31.

Menu path : Logistics Plant Maintenance Maintenance ProcessingOrder Create

SrNo.

Activities Description TCode

1 MaintenanceOrder Cycle

Maintenance order is created from the MaintenanceNotification.Planning operations, Labor resource and materials (ifrequired) in the maintenance order.Check Material Availability.Save Maintenance order and note the OrderNumber.

IW31

2 Permits If permits are assigned then those permits has to beissued by the authorized person.

IW32/IPM2

3 PhysicalMaterialWithdrawnfrom Main

Stores

If required material is available in main storesthen the material needs to be withdrawn fromthe store for executing the maintenance activity.

(The Maintenance Planner will not haveauthorization to post Goods issue from mainstores)

MIGO

4 Execution ofMaintenanceWork

Maintenance team will perform the maintenance taskand restore the Object in Ideal condition.Required material (Spares) will get changed.

NA

5 CompletionConfirmation

Confirms the actual duration and man-hours for theindividual operation.Records the measurement readings from completionconfirmation screen.

IW41

6 Completion ofNotification

Using the Notification tab button, updates thecatalogs on notification screen.

IW22

7 Creation of

settlement rule

For other order types the settlement rule is

automatically created, for them rule has to bechecked for its correctness.

IW32

8 TechnicalCompletion ofOrder

After completion of maintenance notification andentry of tech. Findings, measurement readings themaintenance order has to be completed technicallyto prevent further processing

IW32

9 Settlement ofOrder

After completion of all the activities, maintenanceorder carries all the maintenance cost; these have tobe settled to the proper cost receiver (Cost Center). Accounts department will run the settlement of all themaintenance order periodically to settle themaintenance orders.

KO88/KO8G

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10 BusinessCompletion ofMaintenanceOrder

After settlement of order, the maintenance plannercan close the maintenance order.

IW32

Civil Maintenance: For jobs related to civil maintenance the Plant User will raise

notification of type M1, Maintenance request, for Civil Function locations & alsomentioning the job description required.

The Concerned Civil Planner & Work center will plan for the job in terms ofmaterial & manpower availability.

He will create Order of type PM03 i.e. General maintenance/Request order & getthe material issued.

Remaining all procedures is of same as Break down Maintenance.

1.3 Special Organizational Considerations

None

Sr No Topics3.1 Changes Management Issues

Not Applicable.3.2 Description of Improvements

1. Online information will be available for breakdown and current status of atechnical object.

2. Effective and clear communication of Break down by end user.

SrNo

Gap Analysis

2.1 Gap Identified in proposed solution against Requirements & Expectations

Not applicable

2.2 Impact of Requirement

Not applicable

2.3 Solution Proposed

Not applicable

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3. All record related to technical objects are available at any time for analysis anddecision-making.

4. No separate paper work required to maintain equipment history SrNo

Topics

4.1 Interface / Enhancements considerations

Not Applicable4.2 Reporting considerations

S

No

Reports T Code

1 Breakdown report MCI7, IW29,IW39, IW30,IW40

2 Order operations report IW49

3 Preventive maintenance report IP19, IP24

4 Maintenance cost report MCI8

5 Maintenance report logbook IW676 Equipment history card IE03

7 Defect List MCI5, IW69

8 MTTR/MTBF Equipment MCJB

9 MTTR/MTBF Functional Location MCJC4.3 Authorization considerations

As per organizational needs, not finalized yet. Authorization matrix is being preparedseparately.

Business Process Signoff

ModulePlant Maintenance

Process Breakdown Maintenance

Sub Process /No Breakdown Maintenance & Civil Maintenance JK_BBP_PM_BP_0500

Description Breakdown Maintenance & Civil Maintenance

jk_bbp_pm_bp_0500

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