PREVENTATIVE PREVENTATIVE MAINTENANCEMAINTENANCE

IntroductionIntroduction

Preventative Maintenance Plans are used to create reoccurring Work Orders. SAP Preventative Maintenance Plans consist of:

• Plans • Maintenance Items• Task Lists• Operations• Scheduling Parameters

TerminologyTerminology• Strategy - Is the plan weekly, monthly, yearly, or hourly?

• Start of Cycle - Last time this Work Order was done.

• Shift Factor - Allows you to move the next scheduled PM based on completion date.

• Call Horizon - Specifies when an Order should be generated with reference to a calculated due date. This allows for planning.

• Object List – Actual Functional Location and/or Equipment Stops on a route.

• Maintenance Items – A template that Work Orders are created from.

• Task List - Where operations are maintained and the frequency cycles are determined.

• Operations - Step by Step instructions, Job Duration, and Resources per Work Order. Different frequencies allowed on same Task List.

Five Rules to Create a PMFive Rules to Create a PM1 Determine Strategy

– Due date and frequency

– Does a plan already exist with this strategy that fits needs?

2 Determine the Shift Factors

– Based on completion date

– Based on calendar date

3 Determine the Maintenance Item including Task List

– Can an existing task list be used?

– Create a new task list?

4 Determine if there will be an Object List

5 Determine Scheduling

– Start of Cycle with proper due dates

– Call Horizon

PLANSPLANS

• Contains strategy (weekly, monthly, yearly, Contains strategy (weekly, monthly, yearly, hourly)hourly)

• Contains scheduling parameters (start of Contains scheduling parameters (start of cycle, shift factors, call horizon)cycle, shift factors, call horizon)

• Can consist of multiple maintenance itemsCan consist of multiple maintenance items

MAINTENANCE ITEMSMAINTENANCE ITEMS

• Each Maintenance Item in a plan creates 1 Work Order.Each Maintenance Item in a plan creates 1 Work Order.

• Option to have multiple Items per PlanOption to have multiple Items per Plan

• Work OrdersWork Orders

– Work Order DescriptionWork Order Description

– Functional Locations or Equipment (for history and cost)Functional Locations or Equipment (for history and cost)

– Work Center Work Center

– PlannerPlanner

– Activity TypeActivity Type

– Object ListObject List

• Link to Task ListLink to Task List

TASK LISTTASK LIST

• Consists of:Consists of:

– OperationsOperations

– Maintenance Strategy Maintenance Strategy • WeeklyWeekly• MonthlyMonthly• YearlyYearly

– Maintenance PackagesMaintenance Packages• A Maintenance Package is a list of frequencies A Maintenance Package is a list of frequencies

available to a Strategy. available to a Strategy.

OPERATIONSOPERATIONS

A Task List can contain one to many operations which:A Task List can contain one to many operations which:

– States Work Center ResponsibleStates Work Center Responsible

– Includes long text step-by-step instructionsIncludes long text step-by-step instructions

– Estimates duration of jobEstimates duration of job

– Estimates number of people to do the jobEstimates number of people to do the job

– Appear cyclically on a work orderAppear cyclically on a work order

SCHEDULING SCHEDULING PARAMETERSPARAMETERS

• One Per Plan One Per Plan

• Start of Cycle - When was the last time the Start of Cycle - When was the last time the smallestsmallest cycle of cycle of the Plan executed?the Plan executed?

• Shift Factors - Is the next Work Order from this Plan due based Shift Factors - Is the next Work Order from this Plan due based on Completion of previous W.O., or is it calendar based?on Completion of previous W.O., or is it calendar based?

• Call HorizonCall Horizon -- What percent of the What percent of the smallestsmallest cycle must pass cycle must pass before creating the next due W.O.before creating the next due W.O.

• Scheduling Period - Number of days in future I can view Plan to Scheduling Period - Number of days in future I can view Plan to see what is coming due. (Blank default will always show next see what is coming due. (Blank default will always show next due date.)due date.)

Create Task ListCreate Task List

Task List - HeaderTask List - Header

After Header information is entered, Press the Operation Overview Button

Task List – Operation Task List – Operation OverviewOverview

Update Maintenance Packages

Double-click for Long Text

Task List – Maintenance Task List – Maintenance Pkg.Pkg.

Task List – Operation Long Task List – Operation Long TextText

Create a PlanCreate a Plan

Strategy must be same as task list strategy

Create A PlanCreate A Plan

To hide/unhide the Plan Header information

Enter the Item Description and the F/L then press Enter. Planning Data will default from F/L.

Verify Order Type,Work Center, Planner Group, and Activity Type

Add Objects to a Maint Add Objects to a Maint ItemItem

Object List Tab

Attach Task List Attach Task List

If Task List exists To create new task list

Create another Maint. Create another Maint. ItemItem

Create additional maintenance items

Return to Plan HeaderReturn to Plan Header

Unhide the Plan Header

Set Scheduling Set Scheduling ParametersParameters

Scheduling Parameters tab

Save the PlanSave the Plan

Save

Schedule the PlanSchedule the Plan

Used for one-cycle PlansUsed for multiple cycle Plans

To manually call work orders in Plan

PM OverviewPM OverviewPLAN- Strategy and Scheduling

MAINT ITEMS- Work Order template and Object List

OPERATIONS- Frequencies on Maintenance Pkg.

TASK LIST

STRATEGY

SCHEDULE THE PLAN

PLANS MAY HAVE MULTIPLE MAINT ITEMS. THE STRATEGY OF WEEKLY, MONTHLY, OR YEARLY MUST MATCH THE TASK LIST STRATEGY. THE SCHEDULED PLAN IS BASED ON 1 START DATE – DIFFERENT DATES REQUIRE DIFFERENT PLANS.

EACH ITEM CREATES A WORK ORDER. THE OBJECT LIST CONTAINS THE DIFFERENT FUNCTIONAL LOCATIONS WHERE WORK IS TO BE DONE.

STEP BY STEP INSTRUCTIONS. MAY BE A LINKED DOCUMENT OR INTERNAL TO SAP. A STRATEGY OF WEEKLY, MONTHLY, OR YEARLY IS ASSIGNED TO TASK LIST AND MUST MATCH THE PLAN STRATEGY.

STEPS TO BE EXECUTED FOR THE OBJECTS ON THE MAINT ITEMS. EACH OPERATION CAN HAVE DIFFERENT MAINT PKGS, WORK CENTERS, DURATION OF JOB, NUMBER OF PEOPLE NEEDED, AND LONG TEXT TASKS.

DEFINES THE FREQUENCY AT WHICH SPECIFIC OPERATIONS ARE EXECUTED.

DETERMINES THE START OF CYCLE BASED ON THE LAST TIME THE WORK ORDER WAS DONE. ALLOWS NEXT PRODUCED WORK ORDER TO CHANGE BASED UPON COMPLETION. DETERMINES WHEN THE WORK ORDER SHOULD BE GENERATED TO MEET THE DUE DATE.