jk_bbp_pm_bp_0700

Project Name Title

JK Cement

Calibration Inspection, Measuring & Test Equipments

Version Document ID

1.0s JK_BBP_PM_BP_0700_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

Business Blue Print- Business Process- Plant Maintenance

File Name: Release: ECC 6.0

Responsibility: PM Status: Closed

Copyright © 2011 JKT of 8

IMPLEMENTATION_BLUE PRINT Business Process Details

Module Plant Maintenance

Process Calibration Inspection, Measuring & Test Equipments

Sub Process / No


JK_BBP_PM_BP_090

0

Description Calibration Inspection, Measuring & Test Equipments

Sr No

Business Process Explanation

1.2 Explanation of Proposed Process

The calibration inspection combines functions from the Plant Maintenance (PM) and Quality Management (QM) application components of SAP.

The equipment, for which you want to create a calibration order, must be created as a piece of equipment in Equipment category Q (Test/Measurement equipments).

Maintenance orders provide a means for planning document and history for any calibration inspection job. The Measuring equipment to be calibrated is mentioned as reference object of order, Basic dates and maint. work center performing the calibration inspection are defined in order header, calibration inspection related operations with inspection characteristics are inserted in the operation page of order. The master calibrator equipment can be assigned as a Production resource tool (PRT) in the calibration inspection operations.

For calibration inspection the operations can not be feed directly into order but a calibration task list must be created since inspection point and inspection characteristics can be assigned to operations only in the task list and not in the order. This task list is then inserted in the calibration order while creating the order directly, otherwise the task list is assigned in the calibration plan.

On the other hand QM module’s inspection lot functionality provides inspection results recording facility for calibration inspection readings which are created as quantitative inspection characteristics and assigned to order operations. Valuation and Usage decision after result recording of inspection lot is also done in QM module.





Inspection lot: In the Quality Management (QM) component, quality inspections are processed on the basis of inspection lots. If you want to inspect a specific quantity of a material or a piece of equipment, an inspection lot must be created in the system.

Inspection Lot is a request to a plant to inspect a specific quantity of material or pieces of equipments or functional locations. An inspection lot is documented by an inspection lot record in the SAP System.

Use

The system uses the inspection lot to record, process and manage information for a quality inspection. This information includes:

Inspection processing data such as: o Inspection lot origin o Inspection date o Processing status of inspection lot

Inspection specifications (for example, the task list or material specification according to which the goods/equipment in the inspection lot will be inspected)

Inspection results: o Recorded characteristic values o Recorded defects

Usage decision (a decision that specifies whether the goods or equipment/ functional location in the inspection have been accepted or rejected)

An inspection lot can be created manually by the user or automatically by the system.

Integration

Inspection lots can be created automatically by events triggered in other components of the logistics supply chain. For example:

Goods movements in the Materials Management (MM) component (for example, goods receipt)

Release of maintenance orders in the Plant Maintenance (PM) component.





Cross Functional Reference(s):

Calibration inspection orders are linked or integrated with following SAP modules for different purposes:

QM module: for inspection lot generation from calibration order, result recording and usage decision for calibration inspection lots.

CO module: for order cost display and cost settlement to receivers e.g. cost center after technical completion of order.

Calibration Inspection processing steps:

1. Create Task list for calibration inspection

First of all a task list for calibration inspection will be created according to inspection requirements which will then be assigned in a Calibration plan or can be inserted in the calibration order if order needs to be created directly.

The task list will be general task list with inspection points for equipment. Required inspection characteristics will be assigned to the task list operations.

2. Order creation :

There will be two scenarios for creating calibration order:

1. With reference to the notification(s):

Whenever a notification (Maint. request) will be received from plant that a particular measuring equipment is showing incorrect reading and needs calibration, then a calibration order (type PM06) will be created w.r.t. that notification for doing

calibration of that measuring equipment.

2. Automatically from Maintenance plans:

Calibration orders will be created automatically through Maintenance plans, mainly Calibration plans or Shutdown plans, on their due dates as per the schedule decided for these jobs.

For the first case, calibration can be created by any user having authorization to create the orders and following data will be planned and entered while creating the





calibration order with reference to the notification:

3. Equipment (to be calibrated) in reference object

Insert correct calibration task list in the order operations.

Manual assignment of any permit(s), if required, like process isolation or control isolation/system bypass, for carrying out calibration operations on equipment.

Save order.

For the second case if the order is created from a shutdown plan, then the ‘Revision’ of that shutdown, if any, should be assigned at order header

2. Maintenance order release/ putting in process:

An authorized person like Shift Engineer will check the planned order and then release the order to give the go ahead for executing the planned operations.

Before releasing any automatically created calibration order from a Shutdown plan, the ‘Revision’ of that shutdown, if any, should be assigned at the order header before releasing it.

An order can not be released until all the permits assigned to the order, if any, are issued by authorized person(s) after checking and insuring the required conditions at the job site, required by the permits. So all the permits should be issued before releasing the order.

When order is released following activities take place in background:

PRT availability is checked and message is issued if PRT is not available for the order dates.

Planned cost is calculated based on the resources planned in the order.

Order is scheduled according to the availability of work hour’s capacity in the maint. work center.

A calibration inspection lot is generated from the order, based on the inspection characteristics assigned in the calibration task list operations. The system status ILAS (Inspection Lot Assigned) in order confirms this event.

Following activities can be performed after order is released-

Result recording can be done for the calibration inspection lot generated through order

Usage decision can be given to the calibration inspection lot





Time confirmation of operations can be done after execution of calibration inspection operations

Orders can be technically completed (TECO)

Order cost settlement can be done.

3. Order operations Execution:

This involves following steps

Collection the PRT (master calibrator equipment), if any

Execution of planned calibration inspection operations

Result recording of inspection readings in the inspection lot.

When the inspection results are saved, system will give automatic valuation for the inspection which can be edited manually if required. At the same time the time confirmation of calibration operations can be done from the same screen.

Usage Decision: Usage decision for the inspection lot will be given manually based on the valuation that whether the calibrated equipment is usable or not.

If UD is given for ‘not usable’ then system proposes a status change for that equipment so that the equipment status will become NPRT (PRT not usable). You can edit that proposal to specify that the status should not be changed.

Simultaneously system gives you the option of modifying the Cycle Modification factor of calibration plan if the order was generated from a plan.

When the UD is saved, the calibration order will also be technically completed (TECO) in background, as a result of follow-on function.

4. Settlement and Business completion :

After technical completion, the order will be settled and its Business completion can be done.

1.3 Special Organizational Considerations

NA

Sr Gap Analysis





Sr No Topics

3.1 Changes Management Issues

Not Applicable.

3.2 Description of Improvements

Online history of calibration inspection of measuring equipments and master calibrator equipments will be available using the calibration orders.

Calibration scheduling overview list of the measuring equipments or Master equipments which are covered by any plan can be seen from their equipment masters itself. There you can see all the past and future schedule dates of calibration inspection including last calibration date and next calibration due date according to the schedule.

If calibration inspection of any equipment fails then its system status in equipment master record, changes to NPRT (not usable) automatically while you save the usage decision of its calibration inspection lot as ‘not usable’.

This status tells that the equipment is not valid for use. This status will be removed automatically in the next successful calibration inspection after repairing or correcting the settings of the measuring equipment

when you save the usage decision as ‘usable’.

This gives the online validity status of any measuring equipment or master calibrator equipment.

You can modify the cycle length of calibration plan by changing ‘cycle modification factor’ at the time of Usage decision saving.

This is useful for testing purpose temporarily for evaluating the optimum interval for calibration of any equipment over the period of time.

The calibration order operation time confirmation can be done simultaneously at time inspection result recording is saved for the calibration inspection lot.

Similarly calibration order is technically completed, automatically in background, at the time of usage decision saving for the calibration inspection lot.

This eliminates the need of doing completion confirmation and technical completion of order separately and reduces considerable time of user in

No

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





processing a calibration in the system.

Sr No

Topics

4.1 Interface / Enhancements considerations

Not Applicable

4.2 Reporting considerations

Sr. No. Reports T- Codes

1. Calibration Plan selection criteria IP16

2. Maintenance item selection criteria IP18

3. Graphical Scheduling Overview IP19

4. Calibration Scheduling Overview IP24

5 Dead line Monitoring for Calibration Plans IP30

4.3 Authorization considerations

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

Business Process Signoff

Module

Plant Maintenance

Process Calibration Inspection, Measuring & Test Equipments

Sub Process / No


JK_BBP_PM_BP_0700

Description Calibration Inspection, Measuring & Test Equipments

jk_bbp_pm_bp_0700

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