The document provides an overview of plant maintenance in SAP, including organizational units, master data, notifications, maintenance orders, and more. It discusses key components like equipment, functional locations, bills of material, and catalogs. The objectives of plant maintenance are also outlined, such as maintaining reliable equipment with low downtime and a preventive maintenance plan.

1. Plant Maintenance – Overview
Feb - 2019

2. General Organizational Units
Agenda :
• SAP Overview
• Enterprise Structure
• Master data overview
• Equipment/ Functional Location/ BOM
• Classification/ Maintenance Catalogs
• Notifications
• Maintenance orders
• External services/ Task lists
• Maintenance Plans
• Closing of Notifications/ Orders/ Settlement
• Measurement Points/ Counters/ Documents
• Completion confirmation/ Reporting

4. Business Flow

5. Organization Structure

6. General Organizational Units
• Plant:
• The plant is an important organizational unit in Logistics. From a maintenance
• point of view, the plant represents both a production site within a company and
a location at which operational systems are installed.
• In the above example, there are three plants: 0001, 0002 and 0003.
• Maintenance Planning Plant:
• The maintenance planning plant is the organizational unit in which maintenance
requirements are planned. It is the plant at which maintenance tasks for an
object are planned and prepared. All data that is required for maintenance, such
as maintenance task lists, materials, inventory management of spare parts and
so on, is managed primarily at this plant.
• In the above example, plant 0001 is the maintenance planning plant.

7. General Organizational Units
• Company Code:
• The company code is an organizational unit within Accounting for which all completed
financial accounting transactions can be represented including entering events that
have to be posted and creating all supporting documents legally required for
individual account closing, such as balance sheets and profit and loss statements.
• In the above example, all three plants belong to the same company code.
• Location
• Location can be defined into plant, based on areas in Plant that are responsible for
particular tasks for the equipments installed in that particular location. The person
responsible for a Location is also the contact person who coordinates between the
production and maintenance
• departments.
• In the above example, there could be several complex production systems for each
• plant, with each system representing a separate Location.

8. • Technical and Operational Systems
• The existing operational systems and technical resources (for example, production
• resources/tools, utilities, and test and measurement equipment) are managed
• in the PM component as functional locations and pieces of equipment. These
• terms are explained in more detail in Chapter 3, Representing and Structuring
Maintenance Objects.
• In the above example, Technical and Operational systems are managed at each of
the three plants.
• Maintenance Planner Group
• The planners in a maintenance planning plant are assigned to maintenance planner
groups. Depending on the size and organization of a company, this may be a
separate department (central work scheduling) or a foreman’s or shop floor area.
• In the above example, there could be three maintenance planner groups in the
maintenance planning plant (plant 0001). One group could plan the maintenance of
production systems, the second the maintenance of buildings, and the third the
maintenance of vehicles.
Location related Organizational Units

9. SAP Plant Maintenance
PM
Plant Maintenance
FI
Financial
Accounting
CO
Controlling
AM
Fixed Assets
Mgmt.
PS
Project
System
WF
Workflow
MM
Materials
Mgmt.
PP
Production
Planning
PM
Plant Maintenance
FI
Financial
Accounting
CO
Controlling
AM
Fixed Assets
Mgmt.
PS
Project
System
WF
Workflow
MM
Materials
Mgmt.
PP
Production
Planning

10. SAP Plant Maintenance -
Objectives
• To have Reliable Equipments with low MTTR and high MTBF
• To eliminate repetitive breakdowns and thereby reduce
wastage of valuable resources
• To have a Preventive Maintenance Plan in place that helps to
maintain Equipment Health.
• To eliminate the need to pull out data from different systems
for reporting purposes
• To draw a long term plan for Spares requirement and also
help in Budgeting.

11. Plant Maintenance -
Processes
• Routine/Breakdown Maintenance
- Notification Creation and Processing
- Maintenance Order Creation and processing
• Preventive Maintenance
- Task lists
- Maintenance Plans
• Order Settlement

12. SAP Plant Maintenance –
Major Sub-functions
• Major sub-functions:
– Equipment and spares tracking
– Maintenance work management
– Refurbishment of Maintenance Spares
– Capital Investment Orders
– Preventive maintenance planning
– Maintenance information analysis (PM-IS)
– Measurement Readings & Counter Readings

13. PM –The Various
Components
Maintenance Orders
Notifications
Locations
Cost
Supplies
Parts
People
Plants
Repair Steps
Equipment
Factory
Calendar
Task-list
Maintenance
Plans

14. Structure Indicator for Functional
Locations
Using structure indicators, you can:
• Specify and monitor the generic structure of the functional
location label
• Portray the hierarchy levels within the functional location
structure in the functional location label
• The generic structure of the location label enables the system to
determine a superior functional location and to copy specific data
from it into the new functional location. However, this is only
possible if the functional locations have been created strictly
according to the top-down principle, in other words starting with
the uppermost functional location.

15. Functional Location
• Definition
• The business object functional location is an organizational unit ,that
structures the maintenance objects of a company according to
functional, process-related or spatial criteria. A functional location
represents the place at which a maintenance task is to be
performed.
• Use
• A functional location represents system area at which an object can
be installed. The objects that can be installed at functional locations
are called pieces of equipment in the R/3 System.

16. Functional Location Master Data
• The master record for a functional location contains the
following data groups:
• Location and maintenance data
• This data includes, for example, maintenance plant and cost
center, structure indicator, superior functional location and the
maintenance planning group responsible.
• Partner data
• This is data that describes a certain responsibility for a
functional location, for example, supplier, responsible
employee.
• Measuring points, counters and measurement documents
• You can use the classification system to classify functional
locations according to technical characteristics. The classes
make it easier for you to find similar or identical functional
locations in the system.

17. Equipment
• The business object "Equipment" is an individual, physical object
that is to be maintained independently. It can be installed in a
technical system or part of a technical system.
• You can manage all types of device as pieces of equipment (for
example, production utilities, transportation utilities, test equipment,
production resources/tools, buildings, PCs).
• You define and manage each piece of equipment in the Plant
Maintenance (PM) System in a separate master record and can set
up an individual maintenance history for each one.

18. Equipment Master Data
• General data
• This is fixed data, which generally does not change in the course of time, for
example, the acquisition value of the piece of equipment, its size and
dimensions and the year of construction.
• Plant Maintenance data, location data and sales data
• This is time-dependent data. It can change repeatedly in the course of time.
This data can be, for example, the maintenance planner group, the responsible
work center, the maintenance plant and the cost center.
• Partner data
• This is data that describes a certain responsibility for a piece of equipment, such
as for example, supplier, purchaser, responsible employee.
• Measuring points, counters, measurement documents
• You can classify pieces of equipment by their technical characteristics using the
SAP Classification System. The classes help you to find similar or identical pieces
of equipment in the system more easily.

19. Bill Of Material (BOM)
• Bill Of Material (BOM)
• USAGE
Bill of material usage is used to define the purpose for which a bill of material
can be used (e.g. in production, sales and maintenance).
• Definition
The components of a technical object are located in the items of the
BOM. Item data is only valid for a particular item within the BOM.
• Structure
Items are differentiated by their category (). The item categories are
differentiated by an item category key – N for non-stock item and L for
stock item
• Types :
1. Functional Location BOM
2. Equipment BOM
3. Material BOM
4. Maintenance assembly

20. Maintenance Notifications - Types
• A Maintenance Notification is an information to the concerned department indicating
a Malfunction/Breakdown. Following are the most commonly used types of
Notification:
1. Malfunction Report
2. Maintenance Request
3. Activity Report

21. SAP PM
Structure of a Maintenance Notification
date/time/reported by
description
PM object: functional location
equipment
assembly
location data
account assignment data
breakdown/availability data
Activities
Maintenance
tasks
damage location
damage
cause of damage
Notification
items
Notification
activity
performed by
dates
task description

22. SAP PM
Maintenance Catalogs
Object component Cause of damage Task
Damage Activity
Code
Catalogs for
Catalog structure: Example:
Catalog
Code
Damage
catalog
Mechanical
malfunction
Code
010 Corrosion
020 Breakage
030 Tear
. .
. .
. .
Code group

23. SAP PM
Maintenance Orders
• Definition
Detailed planning assistance for maintenance tasks to be performed.
• Use
1. Plan tasks in detail with regard to type, scope, dates and resources
2. Monitor the execution of tasks
3. Define rules for account assignment, settlement and budgets
4. Enter, assign and settle the costs which arise from tasks

24. SAP PM
• Maintenance Orders can be of the
following types:
– Preventive maintenance orders released
by PM schedules at due dates
– Planned orders arising from maintenance
notifications (Malfunctions and
Maintenance requests)
– Unplanned orders created if immediate
action is required Calibration Orders
– Refurbishment orders
– Capital Investment Orders
Types of Maintenance Orders

25. •THANK YOU