SAP PM Overview

Plant Maintenance

Presentation Title

Page 1

Table of Content

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 2

An HCC Group company

Table of Content

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 3

An HCC Group company

Overview

Plant Maintenance (PM) module

-

Maintenance planning
Maintenance execution
Equipment movement tracking
Equipment usage tracking

Page 4

Agenda

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 5

An HCC Group company

Master Data
Master Data
Measuring Counters

Equipment Master
Functional Location
Equipment BOM
Warranty
Class

Task list
Characteristic
Maintenance Plan

Page 6

Master Data
Master Data

Functional location ( Sub location within plant)

Equipment Master ( individual machine)

Measuring Counter (Shift, Maintenance, Break down, Idle, Production hours, Power consumed etc)

Task list (Preventive maintenance activities with frequency for a group of machine / individual machine)

Maintenance plan ( Assigning task list to individual machine)

Warranty

Page 7

Agenda

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 8

An HCC Group company

Functional Location

Functional location is the sub location Plant

e.g.
Production line 1
Production line 2
Production line 3

Page 9

Functional Location
Structuring Rules

Example 1

XXXX-XNN-NN-XNN

Example 2

AN-ANN-N-X-X

Key:
A=alphabetic
N=numerical
X=alphanumerical

Page 10

Agenda

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 11

An HCC Group company

Equipment
Equipment Classification
Equipment =

Technical system that is to be

maintained individually

Production equipment
Machinery
Test and measuring
equipment
Production resources/
tools (cranes, tools..)

Page 12

Equipment
Contents of Equipment Master Record
Equipment master record
General
Location
Organization
Warranty

Warranty / Partner
Equipment usage

Classification
Documents

Page 13

Equipment
Equipment Status

System status

User status

installed

In production

pre-defined

.
.
freely definable
.

.
.
.

Page 14

Agenda

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 15

An HCC Group company

Maintenance Order

Maintenance order types

e.g. Preventive Maintenance order
Breakdown Maintenance order
Commissioning order
Overhauling order
Calibration & Testing order
Inspection order

Contents of Maintenance order

Technical objects ( e.g. Machine)

Operations ( list of operations to be performed)

Internal resources ( manpower, machine)

Material list ( Spares, Consumables etc)

External services

Schedule dates

Page 16

Process Flow chart

Planning
(Preventive Maint.)

Execution

Maintenance Task List &

Frequency for
maintenance, inspection &
Calibration

Release Maintenance
Order

Maintenance Plan

Scheduling

Activity Confirmation
of Order

Notification

Technical Completion
(TECO)

Breakdown,
Installation &
Commissioning etc.

Order Settlement

Page 17

Good issue

Agenda

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 18

An HCC Group company

Preventive Maintenance
Preventive Maintenance Planning contents

Time based maintenance strategies ( Weekly, Monthly etc)

Performance based strategies ( Hourly, Km etc)

General maintenance task lists

Preventive maintenance plans

Maintenance order scheduling

Start of Maintenance cycle

Maintenance call release

Page 19

Preventive Maintenance
Elements of Preventive Maintenance
Maintenance
Strategy

Maintenance Plan

MAINTENANCE
STRATEGY

MAINTENANCE
SCHEDULE

SCHEDULED
CALLS

MAINTENANCE
ITEMS

MAINTENANCE
ORDERS

Maintenance Order

MAINTENANCE
PACKAGES:
-Time based
-Performance based
- Counter based

-FUNCT LOCATIONS
-EQUIPMENT
-ASSEMBLIES

ACTIVITIES:
- General Task List

Page 20

Preventive Maintenance
Time Based Flow Diagram

Scheduling
Maint. Plan

Order
Confirmation

Auto creation
of Maintenance
Order

Goods Issue of
Spare parts /
Consumables

Order
Completion

Order
Settlement
Page 21

Preventive Maintenance
Performance Based Flow Diagram

Scheduling
Maint. Plan

Goods Issue of
Component

Order
Confirmation

Auto creation
of Maintenance
Order

Measurement
Document
Entry

Order
Completion

Order
Settlement
Page 22

Agenda

Overview

Master Data

Function Location

Equipment Master

Maintenance Order

Preventive Maintenance

Breakdown Maintenance

Page 23

An HCC Group company

Breakdown Maintenance
Create Breakdown
Notification

Goods Issue of
Component

Create Breakdown
Order

Order
Confirmation

Order
Completion

Order
Settlement
Page 24

Thank You

Page 25