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T r a n s f o r m i n g Consulting E n

T r a n s f o r m i n g

Consulting

E n t e r p r i s e s

Project Name

JK Cement

Title

Maintenance Processing: Notifications

Version

1.0s

Document ID

JK_BBP_PM_BP_0100_V1.0

Author

Akhilesh Kumar Singh

Reviewed By

XXXXXXX XXXXX

Date

01.11.2012

Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

File Name:

 

Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

Business Process Details

IMPLEMENTATION_BLUE PRINT

Module

Process

Sub Process / No

Description

Plant Maintenance

Maintenance Processing: Notifications

Maintenance Notification processing

JK_BBP_PM_BP_010

0

Maintenance Notification processing

Sr No

 

Business Process Explanation

1.1

As Is Process General Explanation

 

At

present CCR/Production person enters the breakdown report or maintenance

request for corrective action mentioning the first information report and the timing.

After completion of job the maintenance person hands over the equipment to production and okays the report in compliance report with time of completion.

1.2

Explanation of Proposed Process

 

A maintenance notification, PM notification for short, is used to

 

1. Describe the problem condition of a technical object in the PM System by the plant’s production user for notifying to maintenance department,

2. To refer the maintenance department for a task that needs to be carried out and

3. To document the work performed.

There are three types of maintenance notification available in the standard SAP system in PM module:

1. Malfunction Report:

A

malfunction report describes a malfunction at an object, which affects its

performance in some respect. Using a malfunction report, for example, an

employee in Production can report that a system has reduced or zero performance, or that its output is of a reduced quality.

As

a rule, a malfunction report requires the maintenance department to arrange for

Copyright © 2011 JKT

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Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

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Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

specific repair task to be carried out, for the ideal condition of the object to be restored.

a

2. Maintenance Request:

A maintenance request is a targeted instruction to the maintenance department to

carry out an activity in the manner described. The decisive factor in this case is

that there can be no malfunction.

Maintenance requests can also be used for investments, for example if an

employee requires a new monitor, or if all the telephones in one part of the building

in

a company need replacing.

3.

Activity Report:

An activity report describes a maintenance activity which has already been carried out, and which was not necessary due to a malfunction or request from plant user. It simply provides technical documentation that records which activities were carried out when, at what time and with what results. For this reason, activity reports are used for the technical confirmation of maintenance activities which were not requested and were executed by maintenance department itself by self decision.

Typical examples of the activities documented in activity reports are "Fill up oil" or "Checked Pressure" or "Tighten screws".

Notification structure:

The screens available in different types of notifications will vary according to the requirement.

Notification header

Notification header

Notification Description

Reference object: Functional Location, Equipment, Assembly

Subject: codingcode and short text, Notification description with long text note pad

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File Name:

 

Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

 

Responsibilities: Planner group, Maint. Work center (are copied from ref. object’s master record), Reported by, Notification creation date and time (automatically by the system)

Start/End dates: Priority*, Required start date/time, Required end date/time, Revision**

Malfunction

data:

Malfunction

start

date/time,

Malfunction

end

date/time,

 

Breakdown indicator, Breakdown duration

 

Location data: :

 
 

(is copied from technical object master on which the Notification is created)

Plant, plant section, location, ABC indicator, Cost center, Controlling area, company code etc.

Items: 

 
 

Object partcode with short text, Damagecodes with short text and free text for each damage.

One item represents combination of object part and damage.

 

Causes: 

 
 

Causecodes and short text with reference to each item, free texts for each cause.

Tasks: 

 
 

Taskcodes and short text with reference to each item, free texts for each task.

Planned start date/time, planned finish date/time, completed by, completion date/ time for each task.

*

Priority- Priority is selectable in the notification header from the predefined priorities. Each priority defines a set of Start date and End date formula. When the user selects a Priority according to the requirement, the system automatically assigns the Required start date and Required end date according to the selected priority formula. This saves the time while filling up notification

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Responsibility:

PM

Status:

Closed

data.

** Revision- Revisions are kind of master records which can be maintained in system customization. Revision represents plant overhauling or shutdown in SAP. When a revision is announced in plant then its revision number should be maintained in the system which can be then mentioned in the notifications and orders related to the revision. Each Revision contains revision number, description, Planning plant, start date/time, end date time and completion indicator which is checked when the revision is over so that it can not be assigned to notifications or orders any further.

Revisions provide a very useful selection criterion for getting the list of notifications and orders related to a revision or shutdown for viewing the complete history of jobs related to a shutdown.

Naming and numbering conventions:

Notification number length: 12

It is generated automatically by system at the time of notification creation and saving according to the number range defined in configuration.

Notification description :40 characters

Following Notification types will be maintained for JK CEMENT DIVISION

M1

Maintenance request

M2

Malfunction report (Breakdown Notification)

M3

Activity report

Number range:

Different number ranges will be used for each notification type so that by seeing the notification number series itself, maintenance person will be able to know the type of notification received from the plant.

The notification number will be assigned at the time of notification saving only and not before (at the time of creation), to avoid the wastage of numbers in series, in case a notification is not saved after creation due to some reason.

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Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

File Name:

 

Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

Notification processing steps:

 

1.

Notification creation by plant user/CCR:

There can be Five scenarios for this

 

1)

Production breakdown:

 

Whenever there is a production breakdown due to failure of any technical object in plant, the production user will create a Breakdown Notification (type MF) with following input data

brief description of failure,a Breakdown Notification (type MF) with following input data malfunction start date/time, technical object in the

malfunction start date/time,MF) with following input data brief description of failure, technical object in the reference object screen

technical object in the reference object screen area of header 

 

any other information like problem area code and task code required if he can determine it at that point of time. Please refer Business process document JK_BBP_PM_MD0700 for Catalogs and Codes to be used in Notifications. Please refer Business process document JK_BBP_PM_MD0700 for Catalogs and Codes to be used in Notifications.

 

2)

Equipment fault/ Maintenance request:

 
 

When there is a problem or equipment failure but not a case of production breakdown or if a service from maintenance department to be requested then the plant user will create a Maintenance Request (notification type MR) with following input data

brief description of failure,Request (notification type MR) with following input data Planned start/date, Planned finish date/time,  

Planned start/date, Planned finish date/time, 

 

technical object in the reference object screen area of notification header andPlanned start/date, Planned finish date/time,   any other information like problem area code and task if

any other information like problem area code and task if he can determine it at that point of time.the reference object screen area of notification header and 3. Notification receipt by maintenance department and

3.

Notification receipt by maintenance department and Put in Process (release) :

 
 

Notification will be received by the planner group to which the notification is referred.

Maintenance person will inspect the problem at site if required, enter any technical finding like object part, damage and cause found at that point of time; plan and assign required tasks in the notification. Please refer Business process document JK_BBP_PM_MD0700 for Catalogs and Codes to be used

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Business Blue Print- Business Process- Plant Maintenance File Name: Release: ECC 6.0 Responsibility: PM Status:
Business Blue Print- Business Process- Plant
Maintenance
File Name:
Release:
ECC 6.0
Responsibility:
PM
Status:
Closed
in Notifications.
Authorized person from maintenance department will release or ‘put in process’
the notification which signifies the go-ahead for performing the tasks.
Following activities can not be performed on a notification until it is released-
Completion of the notification tasks after doing the job at site
Complete the notification (NOCO) after finishing all the tasks assigned to the
notification.
4.
Assign Maintenance order:
If the job involves material issuing for repairing and/or any internal/ external
service requirement then a maintenance order will be created with reference
to the notification. Please refer Business process document
JK_BBP_PM_MD0700 for orders.
In other words if the job involves any cost other than nominal work time
devoted by maintenance person in performing the task, you need to create a
maintenance order w.r.t. the notification with operation and/or components
and/or external service requirement planning.
5.
Tasks completion
Each task assigned to the notification will be completed individually after doing
it at site with additional details like completion date and time.
6.
Technical confirmation
All the technical findings e.g., object parts, damages, causes etc not filled
before will be entered.
7.
Notification completion
After completing of all the tasks assigned to the notification, the notification will
be completed at header level. But any technical findings which were not
entered in notification should be maintained before notification completion
(NOCO).
Notification completion is not possible if any of the tasks assigned to it is not
completed.

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Business Blue Print- Business Process- Plant Maintenance

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Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

 

Feed loss in terms of time units, is required in case any production machine is out of operation. For this malfunction start and malfunction finish date/time and breakdown indicator will be used in the notification header of Breakdown notification, created for that production machine/line. This will automatically calculate the breakdown duration which will represent the feed loss of that machine.

1.3

Special Organizational Considerations

 

None

Sr

 

Gap Analysis

No

 

2.1

Gap Identified in proposed solution against Requirements & Expectations

 

Not applicable

 

2.2

Impact of Requirement

 

Not applicable

 

2.3

Solution Proposed

 

Not applicable

 

Sr No

Topics

 

3.1

Changes Management Issues

   

Not Applicable.

3.2

Description of Improvements

   

For any work request to maintenance department, plant user will have to create a notification.

For shutdown declaration also, a notification will be created by the shutdown decision making person with the details like top Functional Location of the section/ area for which the shutdown is planned, required start and required end.

 

An authorized person will create a Revision accordingly in PM module and assign it to the notification for using the functionality of Revisions.

 

Daily routine jobs and self decided jobs by maintenance department which were entered in the shift logbook will now be entered using Maintenance Activity reports.

Online information will be available for breakdowns and problem status of technical objects.

Analysis of repetitive problems will become easy using standard functionality of defect & cause codes. JK CEMENT DIVISION will be able to track faults, cause, task done, object part affected etc.

Less disputes between production and maintenance departments by

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File Name:

 

Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

   

transparent reporting of down time in the notifications.

 

Effective and clear communication of Break down by plant user.

 

Activity report will be helpful in logging of activities done on any technical object, without receiving any request from production users thus providing daily work history similar to logbook.

Minor malfunctions, which do not need detailed operation planning, materials and involves no cost, could be handled by Notifications alone without any need of creating orders.

Tasks from different notifications can be completed collectively at one screen using List of tasks transaction in change mode (T-code: IW66). This will be useful for shift engineer for completing days tasks at one go at the end of the shift.

Similarly Notifications can be released or completed (NOCO) or orders can be created /assigned for notifications collectively at one screen using List editing of notifications in change mode (T-code: IW66).

Notifications can be seen graphically also with all the details like notification header data, reference objects, items, causes, tasks and assigned order etc. using multilevel notification list display.

For seeing the complete logbook for all the tasks done in short, transaction for ‘List of tasks’ (IW67) can be used with selection criteria like notification types= all, reference date from and to etc.

 

For direct orders, automatically generated from maintenance plans like preventive maintenance and calibration etc., the task done should also be maintained in the activity report in short, in the form of one task, for getting complete history from notification tasks itself and these activities need not to be checked additionally from order operations list. That makes the complete logbook using notifications tasks.

Sr

Topics

 

No

4.1

Interface / Enhancements considerations

 
 

Not Applicable

 

4.2

Reporting considerations

 
   

S.No.

Reports

T Code

 

1.

Machine history record

IW67,

W69,

W30

2.

Feed loss (in Hrs) analysis report

IW67,

IW69, IW30

3.

Month wise breakdown report

MCI7, MCI3,

MCI4

4.

List of Notifications

IW28, IW29

4.3

Authorization considerations

 
 

As per organizational needs, not finalized yet. Authorization matrix is being prepared

Copyright © 2011 JKT

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Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

Business Blue Print- Business Process- Plant Maintenance

File Name:

 

Release:

ECC 6.0

Responsibility:

PM

Status:

Closed

separately.

separately.

Business Process Signoff

Module

Process

Sub Process / No

Description

Plant Maintenance

Maintenance Processing: Notifications

Maintenance Notification processing

JK_BBP_PM_BP_010

0

Maintenance Notification processing

Copyright © 2011 JKT

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