1. Plant Maintenance Key User Presentation

2.  SAP - An E.R.P. Package
 Contents of PM Module
 Benefits of PM Implementation
ERP OverviewERP Overview

3.  What is an ‘E.R.P.’ ?
 Why ‘E.R.P.’ is needed ?
 Who are Global ‘E.R.P.’ Vendors?
 What is ‘SAP’ ?
 What is ‘Client Server’ Technology ?
General QuestionsGeneral Questions

4. E.R.P. : ENTERPRISE RESOURCE PLANNING
For managing 4M’s of enterprise EFFECTIVELY.EFFECTIVELY.
MATERIALMATERIAL
MACHINEMACHINE
MENMEN
MONEYMONEY
What is an ERP?What is an ERP?

5. A Standard Software Package taking care of all
the needs of an enterprise.
‘E.R.P.’ integrates business processes across
the whole company.
‘E.R.P.’ provides & helps the enterprise to
adopt latest technology & international
business practices with minimum ease.
Why ERP?Why ERP?

6. Examples of Vendors Providing ERP Packages
 SAP
 BAAN
 JD-Edwards
 Marshall
 People-soft
ERP VendorsERP Vendors

7. Systems, Applications, Products inSystems, Applications, Products in
Data ProcessingData Processing
Walldroff, Germany.
SAP Stands for?SAP Stands for?

8. R/3R/3
Client / ServerClient / Server
COCO
AMAM
PSPS
WFWF
ISIS
MMMM
HRHR
SDSD
PMPM
PPPP
QMQM
FIFI
Integration Of PMIntegration Of PM

9.  Overview Plant Maintenance
 Features of SAP PM
 Master Data Preparation
 Plant Maintenance Business Process
 Report Requirement
 Critical Success Factors
OutlineOutline

10. Overview Of
Plant
Maintenance

11. Definition: Maintenance is an action required to
preserve or to retain the health of equipment.
Importance: Because of the increase in automation
and the resulting high fixed costs of operational
systems, plant maintenance plays a decisive role in the
success of any business. Production system need to be
available 24 hours a day in order to guarantee cost
effective distribution of fixed cost
Plant MaintenancePlant Maintenance

12. Materials Management Finance / Costing
Material master Accounting
Service master Order settlement
Equipment Bill of material Cost center
Spare parts planning Activity pricing
Inventory management
Purchase of materials
Services and contracts
Quality Management Asset Management
Inspection of parts Equipment and Asset link
Calibration
Production Planning Human Resource
PRT Scheduling Man Power Capturing
Plant Maintenance IntegrationPlant Maintenance Integration

13.  The operational systems are managed using functional locations,
equipment & sub-equipment.
 Preventive maintenance and inspection plans which are done at a regular
interval are released at a scheduled point of time.
 Malfunctions and other direct requirements are entered directly as
maintenance notification and forwarded to the respective workshop
responsible for processing.
 Maintenance tasks are carried out using maintenance orders.
 Cost captured in the maintenance order is settled against the respective
production cost center.
 The completed maintenance notifications & orders form the basis for
creating maintenance history.
Plant SupportPlant Support

14. Malfunction,
Request
Activity
Malfunction,
Request
Activity
Maintenance notification
what
when
where
technical info
breakdown
Order creation
Planning of task
who
when, how long
which steps
account assignment
resources
Execution
withdrawal
utilities
procurement
work steps
Technical information
malfunction
causes
objects affected
activity
Maintenance history
Completion
Task
requested
1111
Order
Confirmation
Closing
2222
3333 4444
5555
6666
7777
8888
Operation Maintenance planning Maintenance workshop
Fundamental Maintenance Processing StepsFundamental Maintenance Processing Steps

15. Master Data
Preparation

16.  MASTER DATA
 MAINTENANCE PLANNING
 NOTIFICATION PROCESSING
 PM ORDER PROCESSING ( RUSH / UNPLANNED )
ORDER SETTLEMENT
 PM PROCUREMENT & SPARES MONITORING
 HISTORY & ANALYSES
ContentsContents

17. Master Data
 Functional Location
 Equipment
 Catalog Profile (Object, Cause & Damage)
 Check List (Task List) & Plan
 Equipment Sub-Equipment Relation
 Equipment BOM
 Measuring Points & Counters
 Process Instruments for Calibration
Master Data ProcessingMaster Data Processing

18. Technical Object Management
 Functional location
 Equipment master data
 Permits
 Partner & Addresses
 Object link master data
Bill Of Material
 Location specific BOM.
 Equipment BOM.
 Assembly / Material BOM.
Master RecordsMaster Records

19.  PM Work-Center.
 PM Task-List -> Service sheet
 Functional location
 Equipment
 General
 Measurement Point & Counter
 PM Catalogues.
 PM Material Master
 External Service
Master Records Contd..Master Records Contd..

20. A functional location is an element in a technical
structure, representing an area of a Plant at which
Equipment/s can be installed.
Advantages of structuring functional location
1. Identifying the locations via codification logic.
2. Relationship of Functional Location with
Orgnization
3. Identifying the hierarchical position in structure
4. Generating the reports.
Functional LocationFunctional Location

21. Multilingual texts
Internal note
Equipment usage
Classification
Documents
Partner/Addresses
Measuring points
Permits
Equipment master record
PM data
Location data
Production resources/tools data
Serial number data
General Data
Equipment MasterEquipment Master

22. Advantages of BOM
MATERIALS PLANNING
MATERIAL/SPARES PLANNING
LOCATING MALFUNCTIONS

23. Work CentersWork Centers
It defines the group of workmen's or
single person or machine or multiple
machines responsible for carrying out
the activity. This also indicates who is
supposed to carry out the maintenance.
It can be even machines.

24. PLANT MAINT. HISTORY
PM Order
•Costs
•Materials
•Operations
Equipment Plant Area
(Functional
location)
Notification
MAINTENANCE HISTORY
Notification historyOrder historyUsage list (Instll.Period)
Master Records
•Description of Notif.
•Time data,B/D Hrs.
•Machine/ Object data
•Fault location,Damage
•Causes, Action taken
•Text,Object

25. PM Business
Process

26. Preventive Maintenance (Time /
Performance Based)
Breakdown Maintenance
Maintenance Request / Activity
Refurbishment
Calibration of process instruments
Capital Investments
Key Business ScenarioKey Business Scenario

27. Scheduled
Maintenance
Unscheduled
Maintenance
Maintenance
Plan
Schedule
Plan
Create PM
Orders
Adjust planned
dates if requ’d
Maintenance
Notification
Manually create
orders
Short term
planning in order
Release order
Execute
maintenance
Maint operation
completion confirmation
Technically complete
order
Record technical
data in notification
Complete notification
Settlement
Functional Flow SummaryFunctional Flow Summary

28. NotificationNotification
OrderOrder
ControlControl
ProcessingProcessing
CompletionCompletion
History
Material usage, orders, notifications, PMIS, usage list
History
Material usage, orders, notifications, PMIS, usage list
• Technical Object
• Description
• Date
• Malfunction
•Tasks to perform
• Resources int./ext.
• Components
• Tools
• Availability check
• Release order
• Print papers
• Material withdrawal planned/unplanned
• External procurement
•Time confirmation
•Techn.completion
• Order settlement
• Techn. confirmation
44
55
22
33
11
Steps In PM ProcessingSteps In PM Processing

29. Purchase
requisition
Completion
confirmation
Maintenance orderMaintenance order
Op. 10: Internal processing
Op. 20: External processing
Service confirmation
Goods receipt
Invoice receipt
Purchase order
Activity costs
Activity costs
Material Consumption
External Processing FlowExternal Processing Flow

30. Creation of
service
specifications
Determination
of requirements
Service
acceptance
Invoice
verification
Service
entry
PO
monitoring
Ordering
process
Vendor
selection
Quotation
entry
Bid invitation
- User department
- PM Plant maintenance
- PS Project system
PO Invoice
?
=
RFQ
Procurement StepsProcurement Steps

31. Maintenance orderMaintenance order
Internal Processing
operation 10: ME 3 hours
operation 20: EL 1 hour
External processing
operation 30: EXT 1 hour
Material
2 pcs. Material ABC
Costs
Internal Processing: Rs 500.00
External Processing: Rs150.00
Material: Rs300.00
Total: Rs950.00
Costs
Internal Processing: Rs 500.00
External Processing: Rs150.00
Material: Rs300.00
Total: Rs950.00
Cost ProcessingCost Processing

32.  Plant wise view
 Maintenance Group wise view
 Planner Group wise view
 Equipment wise view
 Functional Location wise view
 Financial Period wise view
 Plan vs Actual cost
Cost AnalysisCost Analysis

33. TYPES OF PM PLANNING
2) Counter based maintenance
A - With maintenance strategy
B - With multiple counter plan
1) Time based planning
MonthMonth
P1 x xP1 x x
P2 x x x x x x xP2 x x x x x x x
kilometerkilometer
P1 x xP1 x x
P2 x xP2 x x

34. PM Reports

35.  List of Breakdown Notifications( Daily &
Monthly)
 Equipment Breakdown History
 MTTR / MTBR / MTBF
 Damage Analysis
 Manufacturer wise Breakdown Analysis
Break Down ReportBreak Down Report

36.  Preventive maintenance schedule
 Preventive maintenance Performance summary
 Preventive maintenance feed back summary(check
list)
 Graphical Scheduling Overview
 Material where used List
 Cost Analysis
Preventive Maintenance ReportPreventive Maintenance Report

37.  Planned (Preventive )Maintenance Cost
 Un-Planned (Breakdown) Maintenance
Maintenance Cost ReportMaintenance Cost Report

38.  Goods Receipt
 Goods Issue
 Spare consumption through Maintenance
Order(261 Mov. type)
 Consumption through direct issue to cost
center(201 Mov. type)
 Consumption actual vs. planned budget
 Material where used List
Spare Parts ReportSpare Parts Report

39. Cost at Work Center level
Cost of Internal Activity, External Services
& Spares
Actual Cost Vs Planned Budget at work center level
Repairs & Maintenance BudgetRepairs & Maintenance Budget

40.  Condition of a particular Equipment/Functional Location can
be managed by Condition Based Monitoring by using
Measuring Points & Counters which is created against
Equipment/Functional Location (Trend Analysis),
Characteristic Vs Time
 The Preventive Maintenance (Internal / External) schedule can
be generated with the help of counters ,In case of External
Processing Purchase Requisitions are generated.
Condition Monitoring ReportCondition Monitoring Report

41. THANK YOU