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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

Breakdown Maintenance

Version

1.0s

Document ID

JK_BBP_PM_BP_0500_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

Breakdown Maintenance

Breakdown Maintenance & Civil Maintenance

JK_BBP_PM_BP_050

0

Breakdown Maintenance & Civil Maintenance

Sr No

Business Process Explanation

1.1

As Is Process General Explanation

1.2

Explanation of Proposed Process

In case of any Break down, Production User/CCR/Maintenance Engrr. generates a Maintenance Notification of Notification type M2. He records the Break down occurrence time, technical object (Equipment/ Function location) affected, & damage or any kind of observation found. Online information of Break down & status of technical object will be available to all.

The maintenance team (Electrical/ Mechanical/Instrumentation) attends the break down and records the malfunction end time, causes & activities performed while attending the break down. Here he can also add tasks if required to be performed afterwards, if some temporary arrangements have been done.

He creates a maintenance order of Order type PM01 to issue materials/spare parts if required from their local stores. If the material is not available in their store a purchase requisition can be made directly from the maintenance order. In operation list of the maintenance order all operation performed, work center used and man power hour utilization is recorded.

Break down indicator in notification, will be marked if break down occurs. External services can also be utilized from maintenance order Spare parts planning can be done using Bill of materials.

Actual/planned/estimated cost incurred on attending break down will be summarized with labor & spares cost separately.

Failure analysis can be recorded.

Copyright © 2011 JKT

Page 2 of 9

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

Refer flowcharts below:

1. General Maintenance process (Internal processing)

2. General Maintenance process (External processing both Material &

Service)

o PROCESS FLOW CHARTS

1.1.1 General Maintenance Process (Internal processing)

Create Notification (Request for maintenance by plant user/CCR)

Create Notification (Request for maintenance by plant user/CCR)

Create Notification (Request for maintenance by plant user/CCR)
Create Notification (Request for maintenance by plant user/CCR)
Create Notification (Request for maintenance by plant user/CCR)
Create Notification (Request for maintenance by plant user/CCR)
-Description of job -Required Start and End times of job -Technical object no. -Technical findings-
-Description of job
-Required Start and
End times of job
-Technical object no.
-Technical findings-
Object part, damage
etc. (optional)
-Tasks to perform

Notification receipt by Maintenance Dept.

Inspection of Machine at site by maint. person

Create Maintenance order for the notification (by Maintenance planner)

-Enter additional technical findings and tasks in the Notification. -Release the Notification (Put in process)

X
X
-Description of order -Technical object details (transferred from Notification) -Assign Maintenance work center
-Description of order
-Technical object details
(transferred from Notification)
-Assign Maintenance work
center (transfers automatically
from the technical object
master record)
-Plan operations in the order
Y
with number of persons
required and work times.
-Plan spare materials with
required quantities
-Assign responsible person
Page 3 of 9

Copyright © 2011 JKT

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

Y Schedule the order (for planned start and end times depending upon the availability of
Y
Schedule the order
(for planned start and end times
depending upon the availability of
manpower at the Maint. Work center)
Release the order
X
Issue spare materials from stores
Execute planned
maintenance work at site
Completion (time) confirmation
(of Maintenance order operations)
Inspection of completed
work at site by authorized
person
-Complete the technical
Findings in Notification.
-Complete the tasks
Technical Completion
Of Maintenance order
(by authorized person)
Notification Completion
(by authorized person)
Settlement
of Maintenance order
(by authorized person)
Business completion
of Maintenance order
(by authorized
person )
Order closed

Copyright © 2011 JKT

Page 4 of 9

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

1.1.2 Maintenance order (External processing)

Create Maintenance order

Create Maintenance order

Create Maintenance order
Create Maintenance order

-Description of order -Technical object details -Plan external service operation in the order. Enter operation

details-

Service description or select service from the standard service

catalog, service quantity & unit, price and vendor (optional).

Schedule the order

Release the order

standard service catalog, service quantity & unit, price and vendor (optional). Schedule the order Release the
vendor (optional). Schedule the order Release the order Purchase requisition for the external service is created
vendor (optional). Schedule the order Release the order Purchase requisition for the external service is created
vendor (optional). Schedule the order Release the order Purchase requisition for the external service is created
vendor (optional). Schedule the order Release the order Purchase requisition for the external service is created

Purchase requisition for the external service is created automatically.

Purchase requisition receipt by Purchase Dept.

Purchase requisition receipt by Purchase Dept. 1.For Non Stock Material purchase requisition is made
Purchase requisition receipt by Purchase Dept. 1.For Non Stock Material purchase requisition is made
Purchase requisition receipt by Purchase Dept. 1.For Non Stock Material purchase requisition is made
1.For Non Stock Material purchase requisition is made 2.Purchase Order is created. Execute internal processing
1.For Non Stock Material
purchase requisition is made
2.Purchase Order is
created.
Execute internal processing
work at site, if any
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order
created. Execute internal processing work at site, if any Copyright © 2011 JKT Create Purchase order

Copyright © 2011 JKT

processing work at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested
processing work at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested

Create Purchase order

at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service
at site, if any Copyright © 2011 JKT Create Purchase order Execution of requested external service

Execution of requested external service by vendor

JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
X
X
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet

Create Service Entry sheet

Y

JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet
JKT Create Purchase order Execution of requested external service by vendor X Create Service Entry sheet

Page 5 of 9

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

Y
Y

Confirm/Accept Services (By entering exact quantity of received services in the Service Entry sheet by an authorized person)

Invoice receipt
Invoice receipt

Bill payment

X
X
Completion (time) confirmation (of Maintenance order operations) Technical Completion Cost Settlement Business
Completion (time) confirmation
(of Maintenance order operations)
Technical Completion
Cost
Settlement
Business completion

Notification Processing

Transaction code for creating Maintenance Notification is: IW21 Menu path is : Logistics Plant Maintenance Maintenance Processing Notification Create Notification type for are: M2: Malfunction Report

1. Identification of Malfunction by Operation or Maintenance department.

2. A Maintenance Notification is created with type M2 in the system depending on requirement.

3. Specifying the Description of the Notification as per the nature of maintenance request or malfunction.

4. Mentioning Object Number and time of request with requisitioner identification in to the notification screen.

5. The initiator of Notification can enter the Technical findings (Object part, Damage or cause of damage etc) if he knows the details.

6. Saves the notification.

7. After the job is completed the production person will put the timing of malfunction end and his identification.

8. Maintenance person has to complete any task assigned to notification and enters the activities.

9. Lastly, the notification has to be completed by the authorized person.

Copyright © 2011 JKT

Page 6 of 9

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

Order Processing

 

The transaction code for creating order is IW31.

 

Menu path : Logistics Plant Maintenance Maintenance Processing Order Create

Sr

Activities

Description

T

No.

Code

1

Maintenance

Maintenance order is created from the Maintenance Notification. Planning operations, Labor resource and materials (if required) in the maintenance order. Check Material Availability. Save Maintenance order and note the Order Number.

IW31

Order Cycle

2

Permits

If permits are assigned then those permits has to be issued by the authorized person.

IW32/

IPM2

3

Physical

If required material is available in main stores then the material needs to be withdrawn from the store for executing the maintenance activity. (The Maintenance Planner will not have authorization to post Goods issue from main stores)

MIGO

Material

Withdrawn

from Main

Stores

4

Execution of

Maintenance team will perform the maintenance task and restore the Object in Ideal condition. Required material (Spares) will get changed.

NA

Maintenance

Work

5

Completion

Confirms the actual duration and man-hours for the individual operation. Records the measurement readings from completion confirmation screen.

IW41

Confirmation

6

Completion of

Using the Notification tab button, updates the catalogs on notification screen.

IW22

Notification

7

Creation of

For other order types the settlement rule is automatically created, for them rule has to be checked for its correctness.

IW32

settlement rule

8

Technical

After completion of maintenance notification and entry of tech. Findings, measurement readings the maintenance order has to be completed technically to prevent further processing

IW32

Completion of

Order

9

Settlement of

After completion of all the activities, maintenance order carries all the maintenance cost; these have to be settled to the proper cost receiver (Cost Center). Accounts department will run the settlement of all the maintenance order periodically to settle the maintenance orders.

KO88

Order

/

KO8G

Copyright © 2011 JKT

Page 7 of 9

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

   

10

Business

After settlement of order, the maintenance planner can close the maintenance order.

IW32

Completion of

Maintenance

 

Order

Civil Maintenance: For jobs related to civil maintenance the Plant User will raise

notification of type M1, Maintenance request, for Civil Function locations & also mentioning the job description required.

The Concerned Civil Planner & Work center will plan for the job in terms of material & manpower availability.

 

He will create Order of type PM03 i.e. General maintenance/Request order & get the material issued.

Remaining all procedures is of same as Break down Maintenance.

 

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

 
   

1. Online information will be available for breakdown and current status of a technical object.

2. Effective and clear communication of Break down by end user.

 

Copyright © 2011 JKT

Page 8 of 9

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

     

3.

All record related to technical objects are available at any time for analysis and decision-making.

 

4.

No separate paper work required to maintain equipment history

 

Sr

 

Topics

No

 

4.1

 

Interface / Enhancements considerations

 
   

Not Applicable

 

4.2

 

Reporting considerations

 

S

Reports

T Code

 

No

1

Breakdown report

 

MCI7, IW29,

 

IW39, IW30,

IW40

2

Order operations report

 

IW49

3

Preventive maintenance report

 

IP19, IP24

4

Maintenance cost report

 

MCI8

5

Maintenance report logbook

 

IW67

6

Equipment history card

 

IE03

7

Defect List

MCI5, IW69

8

MTTR/MTBF Equipment

 

MCJB

9

MTTR/MTBF Functional Location

 

MCJC

4.3

 

Authorization considerations

 
   

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

Business Process Signoff

Module

Process

Sub Process / No

Description

Plant Maintenance

Breakdown Maintenance

Breakdown Maintenance & Civil Maintenance

JK_BBP_PM_BP_050

0

Breakdown Maintenance & Civil Maintenance

Copyright © 2011 JKT

Page 9 of 9