The Plant Maintenance system should support the planning, processing of project related activities

and task like, new equipment construction, creation of manufacturing unit or plant facility for specific
one-time project.

It should give a clear representation of the activities, tasks, costs involved in project and the status
of the tasks.

It also should capture the cost of internal labour and services availed for project work.

It shall provide a base for rational decision making by providing up-to-date information of the
projects, it shall have provision to capture resources required for projects.

All outside project shall capture data using internal orders.

All in house projects shall capture data using maintenance orders.

Equipment built using maintenance order shall be capitalized on completion of project.

3 Explanations of Functions and Events

Project process is need based and is carried out at required time for production or other requirements.
Project is taken up for execution as decided by management.
planning is done.

Based on the guidelines project

Project planning is done based on various parameters given by management like project start date,
project completion target date, list activities required to be performed, sequencing of the activities,
resources required to perform each of the activity, approved budget to complete the project.
Two project types are identified for mapping. First is the one, where we develop an entire or part
of plant along with infrastructure and the equipments. On completion, these sites are handed
over to outside parties. All such projects, where we are handing over the developed sites to
outside party and generating revenue, shall be captured through Internal orders. Costing team
shall create the internal orders; maintenance team shall provide necessary data to costing team.
Second type of project, where it is performed for internal usage purposes. In such projects, on
completion of project, the equipment / functional location created shall be capitalized.

Project Planning
Project planning includes various important parameters like
Project start date
Project end date
Budget for completion of project
Detailed list of activities with dependencies
Resources required
Maintenance person prepares detailed project plan, which is based on the parameters mentioned
above.
Maintenance person shall contact master data maintenance team for creating technical objects in
system, which are planned in project plan.
Once the technical objects are created in system, maintenance person shall create a project
maintenance order of type Project order.
Maintenance person shall input the list of activities in system along with resources e.g. material, tools

required to perform the task. All operation dependencies can be defined at this point of time. System
provides option of graphically defining the dependencies.
Wherever necessary maintenance person shall attach safety or work permits.
With the help of project maintenance order, maintenance person shall check availability of the material
in system. If required material is not available, then maintenance person shall initiate procurement of
such materials by manually creating purchase requisition.
Maintenance person shall identify the services required to be taken from external agencies.
Procurement of such services shall be initiated by manually creating purchase requisitions.
Procurement of material and services shall happen as per MM procedure.
Maintenance person shall get approval of budget for the Project maintenance order from the
competent authority.
Maintenance person shall create Asset under Construction (AuC) from the project order.
Maintenance person can get planned cost from the project maintenance order.
On completion of project planning, maintenance person shall release the maintenance order for
execution.
Maintenance person then shall carry out the work as defined in project order. Sequence of the
operation shall be as defined in the project order. Maintenance person shall get the material issued
from the stores.

Wherever required, maintenance person shall get the permits issued by competent authority.

Upon completion of task, maintenance person shall confirm the operations timely.

Project order captures the actual cost of material consumed and activities confirmed, as and when it
happens.

In case, where external agency performs work, maintenance person shall create service entry sheet
for the services availed. Upon acceptance of service entry sheet by his superior, the cost of it gets
captured in project order.
System gives error message, if actual cost exceeds the budget. In such case, maintenance person
shall take action to revise the budget.

Upon completion of project, FICO team settles the project. The cost gets settled to Asset under
Construction.

FICO team creates an asset to which this cost gets settled.

4 Business Model
Refer flow chart - Annexure -KEvent Process Chart Annexure L
5 Changes and its Implications
In case of Maintenance, no legacy system exists. All of the maintenance end users are required to be
familiarized with the concept of Plant maintenance.
All of the end users shall help in preparing and providing the necessary master data, as master data is
the most important part of the Plant Maintenance system.
All end users shall always update or inform the concerned to update the change in master data from
time to time. Any delay in updating master data may result in unwanted or incorrect output from the
system.
In most of the places, the maintenance planner is the person, who also handles the maintenance
workforce; as such he will have to plan the job and the required resources. Also he will have to
carryout the job with the decided workforce.

6 Descriptions of Improvements

The status management of the maintenance order can be used for tracking the progress of
the project.

Online checking of notification and maintenance order compliance with

backlog list will be available.
Breakup of project cost can be obtained based on internal labor, material
consumed and external services.
Material consumption can be tracked for each of the job performed.
Individual maintenance task can be scheduled in relation to other tasks in
maintenance