Consulting

Transforming

Enterprises

Project Name

JK Cement

Title

Preventive Maintenance

Version

1.0s

Document ID

JK_BBP_PM_BP_0600_V1.0

Author

Akhilesh Kumar Singh

Reviewed By

XXXXXXX XXXXX

Date

01.11.2012

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

IMPLEMENTATION_BLUE PRINT
Business Process Details

Module
Plant Maintenance
Process
Sub Process /
No
Description
Sr
No
1.1
1.2

Preventive Maintenance
Managing Preventive, Running ,Shut Down &
Maintenance Logging

JK_BBP_PM_BP_
0600
Managing Preventive, Running ,Shut Down & Refractory Maintenance,
Maintenance Logging

Business Process Explanation

As Is Process General Explanation
Explanation of Proposed Process
Task list Master data will have to be created which incorporates all predefined operations to be
performed & spare parts planning which will be required to perform the activity.
Maintenance Plan has to be created which decides time based or performance based planning
has to be done for the technical object. All scheduling parameters have to be defined on basis of
which schedule has to be generated.
Task List to be attached with this maintenance plan
Also the call object i.e. Notification, Maintenance Order, Service Entry Sheet
Which should be created for processing on due date has to be defined.
Schedule the maintenance plan.
Call object will be generated on the due date.
If the equipment is not free on the due date, it can be planned for some other date.
All maintenance activity performed can be recorded in the notification. Catalog master will be
created for this.
Measuring point Master data will have to created against which specific readings have to be
measured for the standard checks to be performed.
In Performance based maintenance plan Measuring point is Counter, which has to be updated
regularly with actual reading on basis of which maintenance date is decided.
Measurement document has to be created for the Measuring points (associated with object)
that record all values of checks performed on the equipment. Other wise it will have to be
written down in text.

Copyright 2011 JKT

Page 2 of 6

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Shift factor & Tolerance will be used to control generation of future calls if the current
call has been delayed due to any reason
All information regarding Break down & other details will prompt automatically on the
screen while processing order of that particular object.
All cost analysis on labor & material used in preventive maintenance can be done.
The Maintenance schedule will be available online.
All the records of work analysis and material & labor used, cost will be same as of
break down process.

Sr.
No.
01

Activity

Description

T Code

Creation of task list

Task list is created for the technical object

IA01/ I
whose maintenance plan has to be created
A05/ IA11
IP41/
02
Creation of
The cycle time is mandatory field to fill.
Maintenance Plan
If its a counter based plan then the counter
IP42/ IP43
(Based on the
no. has to be given and initial counter reading
existing maintenance should be entered by measuring documents.
plan, it is proposed to
The technical object is assigned for which
have single cycle plan) maintenance plan is required.
The respective task list is assigned.
All the scheduling parameters is filled such as
call horizon depending on time factor required
for the call object to be called in advance,
scheduling period etc.
03

Scheduling
Maintenance plan is scheduled so that the
Maintenance Plan
planned dates and call dates are displayed
04
Deadline Monitoring Select the maintenance plans, which are to be
scheduled or released.
Enter the numbers of days in call objects for
the next n days field to generate the call for the
next specified days.

IP10
IP30

Process Flowchart:

Copyright 2011 JKT

Page 3 of 6

Preventive Maintenance
Maintenance Planner

Operation

Maintenance

Stores

Business Blue Print- Business Process- Plant

START
Maintenance
Creation of Task
lists

File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

1
Refer to
next page

Creation of
maintenance plan

Yes
Maintenance plan
scheduling

Material Issued
by stores

Yes

Material
Requirement

External
services
required

No

Order
Call Object

No

Release Order.

Notification

Issue permit

Notification

Process
Notification

Issue permit
Order

Execute
the job

Execute
the job
Return the permit

Update the
notification and
measuring point if
any

Confirm the
operation and
enter
measurement
reading if any

2
Refer next
page

Complete the
notification

Technically
complete the
order

End

End

Return the permit

Purchase

Maintenance

F&A

1
refer prev
page

Contract Exists

Copyright 2011 JKT

No

Release the order

and get the PR no.

Create PO on the
basis of PR

Page 4 of 6
yes

Enter contract
number in the
external
operations with
services in
maintenance order

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

1.3

PM

Release:

ECC 6.0

Status:

Closed

Special Organizational Considerations

NA

Sr No

Gap Analysis

2.1

Gap Identified in proposed solution against Requirements & Expectations

Not applicable
Impact of Requirement
Not applicable
Solution Proposed

2.2
2.3

Not applicable
Sr No
3.1

Topics
Changes Management Issues
Not Applicable.

3.2

Description of Improvements
Standard maintenance procedures will be available to all maintenance users as a ready
reference.
Repetitive task list can be copied to similar technical objects.
Task lists can be directly adopted into a maintenance order therefore reduced data punching and
planning while preparing an order.
All related aspects like maintenance strategy, frequency of operations to be performed, material
required for performing task, counter readings etc could be directly linked with task list for best
utilization.

Sr No
4.1
4.2

Topics
Interface / Enhancements considerations
Not Applicable
Reporting considerations
Sr. No.
1.
2.
3.
4.
5
6

Reports
Maintenance Plan selection criteria
Maintenance item selection criteria
Graphical Scheduling Overview
Maintenance Scheduling Overview
Dead line Monitoring for Maintenance Plans
Monthly Maintenance Schedule list

Copyright 2011 JKT

T- Codes
IP16
IP18
IP19
IP24
IP30
IW28,IW38

Page 5 of 6

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Business Process Signoff

Module

Plant Maintenance
Process
Sub Process /
No
Description

Preventive Maintenance
Managing Preventive, Running ,Shut Down &
JK_BBP_PM_BP_0600
Maintenance Logging
Managing Preventive, Running ,Shut Down & Maintenance Logging

Copyright 2011 JKT

Page 6 of 6