SAP PM Plant Maintenance Management

1. SAP Plant Maintenance
Overview
Author: Alhadi A. Nibel
SAP PM Associate Consultant

2. Plant Maintenance in the R/3 System
Plant Maintenance:An overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing
Business Process of Plant Maintenance
SAPTransactions
Course List

3. Plant
Maintenance in
the R/3 System

4. Plant Maintenance in the r/3 System
• Plant Maintenance (PM) is a high-performance application component
integrated in the logistics chain of the R/3 System that supports you when
carrying out all maintenance tasks
• The Plant Maintenance component supplements resource planning for
the maintenance of your production systems, vehicles, buildings and so on,
across all branches of industry.

5. PM application component has already been
successfully implemented
• Automotive industry
• Chemical industry
• Commerce/service industries
• Energy suppliers
• Electronics industry
• Food industry
• Mechanical engineering
• Metal-working industry
• Mining industry
• Paper industry
• Petrochemical industry
• Pharmaceutical industry
• Precision engineering
• Primary industries
• Public service industry
• Publishing industry
• Software and computing
• Steel industry
• Transportation industry

6. Plant
Maintenance:
An overview

7. What is SAP Plant Maintenance
• Plant Maintenance is a function or an essential support system in an
industrial process.This system helps and keep all the machinery and
infrastructure into prime condition or ideal in terms of quality and
operational.
SAP Plant Maintenance comprises the following activities:
• Inspection
Determining the actual condition of a technical system
• Preventive Maintenance
Maintaining the ideal condition of a technical system
• Repair
Restoring the ideal condition of a technical system

8. Organizational
Structure

9. Organizational Structure
• Maintenance Planning Plant: Plant in which maintenance tasks are planned
and prepared. Example: Maintenance planner group, maintenance work
centers
• Maintenance Plant: Plant in which the technical objects of a company are
installed. Example: Building, production area

10. Master Data
in SAP PM

11. Master Data in SAP PM
SAP PM:
Master
Data
Functional
Location
Equipment
Bills of
material
Measuring
Point/
Counters
Class/
Characteristics
Work
Centres

12. Maintenance Work Center

13. Structured Clarification Functional Location
Functional locations enable you to structure maintenance
objects according to the following criteria:
• Functional (for example, ”pump station,” ”power unit”)
• Process-oriented (for example, ”polymerization,” ”condensation”)
• Spatial (for example, ”hall,” ”location”)

14. • A piece of equipment is an individual physical object maintained as an autonomous unit.
Pieces of equipment usually represent single objects such as pumps, motors, vehicles, for
which maintenance tasks should be performed and recorded.
• Equipment can be installed at functional locations.A piece of equipment can be linked with
a material, if there is inventory management, in the sense of Materials Management, for
the object.
Equipment Hierarchy

15. Structure of a Bill of Material
An individual bill of material can be defined for each maintenance object.
The bill of material contains the following information:
• Structure of the unit (using assemblies)
• Spare parts for its maintenance (for example, stock items, external material, documents, and texts)

16. Maintenance
Processing

17. Workflow-Supported Maintenance Processing for
Unplanned MaintenanceTasks

18. • Direct creation of a maintenance order
Order
Notification
Notification
Notification
Notification
Notification
Order
Order
Order
• Creation of a maintenance notification with immediate order
• Creation of a maintenance order based on a notification
• Combination of maintenance notification to make a order
Planning MaintenanceTasks

19. What is different between Notification andWork Order
• Maintenance Notifications
are Reporting objects to
record:
Maintenance requirement
Cause, Object Impacted,Tasks
due & Activities Performed
• Types: Maintenance Request,
Malfunction (Breakdown)
Report, Activity Report,
Service Notifications
• Maintenance Notifications
generally do not record Costs
• Maintenance Orders are a complete
record of:
Operations performed
Components used (Stock/Non stock)
External Services
Time, plan costs and actual costs
posted
Settlements executed
• Types: Breakdown Orders,
Corrective Orders, Predictive Orders,
Refurbishment Orders, Preventive
Orders

20. Business
Process of
Plant
Maintenance

21. Breakdown
Maintenance
Corrective
Maintenance
Preventive
Maintenance
Refurbishment
of Spare Parts
Business Process of Plant Maintenance

22. Breakdown Maintenance Processing
Notification
Scheduling
Execution
Completion
Technical object
Description
Date
Malfunction
Order release
Printout
Capacity leveling
Availability check
Planned/unplanned mat. withdrawal
Time conf.
Tech. completion
Order settlement
Technical confirmation
Maintenance
planner
Technician/
Storeperson
Maintenance
supervisor
Malfunction Reports Malfunction Order
History
Material usage, orders, notifications, PMIS, usage list

23. Corrective Maintenance Processing
Notification
Planning
Scheduling
Execution
Completion
Work to be performed
Internal/external resources
Material
Tools
Technical object
Description
Date
Malfunction
Order release
Printout
Capacity leveling
Availability check
Planned/unplanned mat. withdrawal
Time conf.
Tech. completion
Order settlement
Technical confirmation
Maintenance
planner
Technician/
Storeperson
Maintenance
supervisor
Internal External Service Material

24. Stock Material Process Flow (Reservation)
Create
Notification
(IW21)
Create Order refer
from Notification
(IW22)
Order Planning,
Assign operation,
CTRL Key PM01,
Input Stock Material
(IW32)
Order Release
(IW32)
Goods Issue
Material
(MIGO)
Order
Confirmation for
ActualWork
(IW41)
OrderTechnical
Completion
(IW32)
Order
Settlement
(KO88)
Order Closure
(CO99)

25. Procurement Non-Stock Material Process Flow
Create Notification
(IW21)
Create Order refer from
Notification
(IW22)
Order Planning, Assign
operation, CTRL Key PM01,
Non-Stock Material
(IW32)
Order Release
(IW32)
Release Purchase
Requisition
(ME54N)
Create PO refer from
Purchase Requisition
(ME21N)
Release PO
(ME29N)
Goods Receipt from
PO
(MIGO)
Usage Decision/Quality
Inspection
(QA32)
Order Confirmation for
Actual Work
(IW41)
Order Technical
Completion
(IW32)
Sys. Status - TECO
Settlement a
maintenance order
(KO88)
Order Closure
(co99)

26. SAP
Transactions

27. Func. Loc, equipment, and BOM Structure List

28. NotificationTransaction

29. Maintenance OrderTransaction

30. Report List of Order

31. Thank you
• Contact information:
Phone: (+62) 812-9790-0097
E-mail: alhadiakbar.official@gmail.com
Krakatau Consulting – PT Krakatau InformationTechnology
SAP Services & EBM Partner