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SAP R/3
I. MANAGING MASTERS
II. MANAGING MAINTENANCE PROCESSES
III. MANAGING REPORTS
I. MANAGING MASTERS
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
CONTENTS OF MAINTENANCE
OF MASTERS
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Plant
Main Planner Group
Plant Section
Main Work Center
Cost Center /Internal Order
Category
Company Code
Strategy
UOM
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
CONTENTS OF MAINTENANCE
OF MASTERS
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Function Location
Structure
Function Location Category
Plant
Code
Structure Indicator
GIL
Edit Mask
AAA-AANN-AAX-AAX-XXX-XXXXX
Hierarchy Levels
Example
Hierarchy
Level
Edit Mask
Code
Description
Level 1
AAA
GIL
Level 2
AANN
RC01
Level 3
AAX
RC1
Level 4
AAX
CM1
Level 5
XXX
FEG
Level 6
XXXX
Presentation Title | Confidential | Document ID
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
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4.
5.
6.
7.
8.
9.
CONTENTS OF FUNCTIONAL
LOCATION MASTER
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Description
Hierarchical
10
11
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
12
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Equipment Category
Plant
Functional Location
Main Planner Group
Tech. Object Type
Plant Section
Main Work Center
Cost Center /Internal Order
Company Code
Class
Warranty data
EQUIPMENT CATEGORY
13
EQUIPMENT CATEGORY
CATEGO
RY
14
EQUIPMENT
EXAMPLES
AUTOMOBILE
CARS/JEEP/MOBILE VAN
CIVIL OBJECTS
BUILDINGS/CIVIL EQUIPMENTS
DUMMY EQUIPMENTS
ELECTRICAL EQUIPMENTS
MOTORS/TRANSFORMERS/SWITCH
GEARS
INSTRUMENT EQUIPMENTS
RTDS/PROXIMITY SWITCHES/FIELD
INSTRUMENTS/PANELS
MECHANICAL EQUIPMENTS
GEAR BOXES/DPC/DBC/BELT
CONVEYORS
MINES EQUIPMENTS
SHOVELS/DUMPERS/DRILLING
MACHINES
EQUIPMENT CATEGORY
CATEGOR
Y
EQUIPMENT
EXAMPLES
PROCESS EQUIPMENTS
CYCLONES/HOPPERS
QC TEST EQUIPMENTS
PRODUCTION RESOURCES/TOOLS
CRANES
TPP/DG EQUIPMENTS
TURBINE/ECONOMISER/BOILER
UTILITY EQUIPMENTS
COMPRESSOR/WATER PUMPS
NOTE:
ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO
TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT
CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.
15
Category
Number
Range
To
Mechanical Equipments
10000000
19999999
Electrical Equipments
20000000
29999999
Instrumentation Equipments
30000000
39999999
Process Equipments
40000000
49999999
50000000
59999999
Mines Equipments
60000000
69999999
70000000
79999999
16
Description
Number range
From
Automobiles Equipments
80000000
89999999
Safety Equipments
90000000
99999999
QC Test Equipments
1000000
1999999
17
ME_GEARBOX
Gear Box
EL_MOTORS
Electrical Motors
ME_FANS
Fans
PLANNING PLANT
18
19
PLANT SECTION
Plant Section is a division of Maintenance Plants into Production
Areas.
Plant
GC01
GC01
GC01
GC01
GC01
20
Category
Description
RM1
Raw Mill -1
CO1
Coal Mill -1
KL1
Kiln -1
CM1
Cement Mill -1
PP1
Packing Plant -1
PLANNER GROUP
21
PLANNER GROUP =
MCM
ECM
ICM
Mechanical
Electrical
Instrumentation
=
=
=
+
+
+
Cement Mill
Cement Mill
Cement Mill
Mechanical
22
Electrical
Instrumentation
Process
Creation of Equipment-[IE01]
Change of Equipment-[IE02]
Display of Equipment-[IE03]
List Editing of Equipment-[IH08]
Display ( Multi Level)-[IE07]
DISPLAY CONTENTS:
Display of Usage List
Display Action Log
Display Object Information
Installation & Dismantle
23
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
24
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Class Type
Class Group
Characteristics Group
Unit of Measure for
Characteristics Master
CLASS
Classes are :
25
CHARACTERISTICS
26
CLASS
Electrical
Mechanical
Class
Description
Class
Description
GEARBOX
GEARBOX
LTMOTOR
LT MOTOR
BUCKETELELVATOR
BUCKET ELELVATOR
LTFEEDER
LT FEEDER
BALLMILL
BALL MILL
BATTERY
BATTERY
BAGHOUSE
BAG HOUSE
BREAKER
BREAKER
27
PM_EQ_GENL
PM_EQ_INST
PM_EQ_MECH
PM_EQ_MINE
PM_EQ_PROC
PM_EQ_SAFE
PM_EQ_TPDG
28
29
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
30
Plant
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
31
32
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
Functional Locations
Equipment Master
Class & characteristics
MICs
Plant
Work Center Category
Control Key
Cost Center
5. Work Center
6.
7.
8.
9.
33
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Work Unit
WORK CENTER
Work Center is a Person/Group of Persons, who perform Maintenance Activities.
Work Center Category
Each Department will have two categories, Permanent and Contractor.
Category
Description
0021
0022
Mechanical Permanent
Mechanical Contractor
34
35
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
36
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Equipment Master
Function Location Master
Category of Measuring Point
Characteristics
Unit of Measures
MEASURING POINT
It is a Measurement characteristic/Parameter attached to an Equipment
Describe the Physical and/or Logical Locations of Equipment
at which a Condition / Parameter is to be measured.
Measuring Point will be always for an Equipment or FL or assembly
but Generally for Equipments.
Measurement readings are taken for an Equipment at regular
interval to know the Condition at that time.
37
MEASURING POINT
Continued..
38
DISPLAY CONTENTS:
Transfer of Measuring point
39
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
40
Function Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
Group Coding
Counter
Planning Plant
Maintenance Strategy
Work Center
Set of Operations
MIs
TASK LIST
41
Codification Logic for defining Task List Group - It has to be Planning Plant / Maintenance Specific
XX
XX
XX
Example:
42
GCM-GBH-PM 1M Checks
GCEMODPM
GCE-Motor-DC-PM 3M Checks
MAINTENANCE STRATEGY
43
Age of Equipment
Design of Equipment
Importance of Equipment in Production Process
Maintenance Practices of Organization.
MAINTENANCE STRATEGIES
Are 1W / 2W / 1M / 3M / 6M / 1Y
GILMON-- Frequencies Specified in GILMON
Are 6M/ 1Y/ 2Y/ 5Y
MINEHR -- Frequencies Specified in MINEHR
Are 100HR/ 300HR / 350HR/ 400HR
PERFHR -- Frequencies Specified in PERFHR
Are150HR / 250HR / 500HR/ 1000H
44
Continued..
APPLICATION:
Continued..
45
MAINTENANCE PACKAGE
Strategy GILDAY
Cycle Length
UOM
DAY
Weekly (1 Week )
1W
14
DAY
Fortnightly (2 Weeks )
2W
28
DAY
Monthly ( 4 Weeks )
1M
84
DAY
Quarterly ( 12 Weeks )
3M
168
DAY
6M
336
DAY
Yearly ( 48 Weeks )
1Y
Cycle Length
UOM
MON
Half yearly
6M
12
MON
Yearly
1Y
24
MON
2 Yearly
2Y
48
MON
5 Yearly
5Y
Strategy GILMON
46
MAINTENANCE PACKAGE
Continued..
Strategy MINEHR
Cycle Length
UOM
96
HR
P1
312
HR
P2
360
HR
P3
408
HR
P4
504
HR
P5
1008
HR
P6
1512
HR
P7
2016
HR
P8
2496
HR
P9
3000
HR
1P
47
MAINTENANCE PACKAGE
Continued..
Strategy PERFHR
48
Cycle Length
UOM
144
HR
P1
240
HR
P2
504
HR
P3
1008
HR
P4
2496
HR
P5
4032
HR
P6
8064
HR
P7
12096
HR
P8
16128
HR
P9
24192
HR
1P
32256
HR
2P
49
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
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5.
6.
7.
8.
9.
50
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
MAINTENANCE ITEM
51
MAINTENANCE MASTERS
BASIC MASTERS
1.
2.
3.
4.
5.
6.
7.
8.
9.
52
Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan
MAINTENANCE PLAN
53
54
Continued..
55
56
MAINTENANCE PROCESSES
BASIC PROCESSES
1.
2.
3.
4.
5.
6.
7.
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
57
Creation of Notification
Creation of Orders
Execution of Orders
Confirmation of Orders
Technical Confirmation of
Orders
Creation of Purchase Request
Creation of Purchase Orders
Service Entry Sheets
Creation of Measuring Points
& Measuring Documents
Installation / De-installation of
Equipments
1.
2.
3.
4.
5.
6.
7.
58
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders
Go to T. Code - IW39
Selection of Orders
Execution of Orders
Confirmation of Orders
CRTD, CNF ,
TECO & CLSD
ORDER TYPES
PM01 --- PREVENTIVE MAINTENANCE ORDERS
User can not generate PM Work Order for this Order Type externally.
This Order type will help User to find out Cost of Preventive Maintenance
exclusively for his Plant section/Planner group.
60
User will get Preventive Maintenance Orders under Maintenance Activity Type PVM , Annual Maintenance Contract Orders under Maintenance Activity Type AMC and Inspection Orders under Maintenance Activity Type INW
ORDER TYPES
Continued..
61
ORDER TYPES
Continued..
62
ORDER TYPES
Continued..
63
ORDER TYPES
Continued..
64
All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/
Foundation
Presentation
Title | Confidential
Document
ID | Aug
18, 2015
etc are
covered
under| this
Order
Type
and MAT-CIV
65
Order Type
Description
PM01
PVM,AMC,INW
PM02
BDM,WAR,INS
PM03
SDM,OPP,WFM
PM05
Calibration Order
CAL
PM06
CRM,WHY
PM07
CBM
PM08
GEN
PM09
Repairs Order
RWS,RVN,RET,REW
PM10
Improvement/Modification Order
IMO.CON
PM11
CAP
PM12
CIV
QCAL
CAL
Go to T. Code - IW39
Selection of Orders
Execution of Orders
Confirmation of Orders
CRTD, CNF ,
TECO & CLSD
67
Go to T. Code - IW32
Enter number of Selected Order
Release PM01 Type Selected
Order
Go to Operation TAB and
Change operations etc if reqd
Select operation & Go to
Component TAB if Material
Required
Select required Component
Enter reqd Qty , Item category,
Storage Location & Batch
Come to Header data Tab
Enter Start Date & Time
68
69
Selection of Orders
Execution of Orders
Confirmation of Orders
Go to T. Code IW44
Select Header Menu
Confirmation
Select via operation list in
Confirmation Menu
Selection of operation list
appears
Enter Plant
Enter Order type
CRTD, CNF ,
TECO & CLSD
71
72
Technical Completion of
Order
Go to T. Code - IW32
Selection of Order Screen
appeared
Flag In process check box
Enter Order Type PM01
Enter Period (Date fromto)
Enter Status exclusive in
Multiple Selection
CRTD, REL ,
TECO & CLSD
73
Button
1.
2.
3.
4.
5.
6.
7.
75
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
Creation of M2 Notification
Go to T. Code IW21Create
Notification
Enter Notification Type
Do not Enter Notification
Number
Notification Tab Screen Appears
Click Enter Button
Enter Notification Description
Enter Equipment / FL /
Assembly (as required)
76
Manual Process
System Generated
NOTIFICATION TYPES
Continued..
77
NOTIFICATION TYPES
Continued..
78
NOTIFICATION TYPES
Continued..
M5: RECOMMENDATION/IMPROVEMENT
This Notification is generated by User for any improvement/development to be
implemented .
The source for Improvement/Modification/Development in Reliability/ Availability
/Maintainability may be WHY-WHY Analysis, Experts/Consultants
recommendation/Other Units/KIPs etc
The number of such Notifications will be an indicator of improvements done by
User
These notifications will give List of Improvements done by User which is required
by WCM or for sharing with other Units.
M6 --- WORK REQUEST-WORKSHOP
This notification is raised by User on workshop requesting its services for
Repair/Machining/Replacement of Spares/Assembly/Equipment etc.
79
NOTIFICATION TYPES
Continued..
80
Notification Types
Notification Type
M1
M2
M3
M4
M5
M6
81
Description
Maintenance Request
Malfunction, B/Down
UnsafeCond./Accident
Abnormality Record
Recommendation
Work Request- W.Shop
Creation of M2 Notification
Go to T. Code IW21Create
Notification
Enter Notification Type
Do not Enter Notification
Number
Notification Tab Screen Appears
Click Enter Button
Enter Notification Description
Enter Equipment / FL /
Assembly (as required)
82
Manual Process
System Generated
83
If equipment Under
warranty
Selection of M2 Notification
Go to T. Code IW28 Selection
of Notification
Flag check box Outstanding or
In process (as Reqd)
Enter Notification Date
Enter Planner group
Select from Drill Down
84
85
86
Execution of M2 Notification
(Order not generated)
M2 Notification selected in
Changed Mode as explained in
pervious Process
To Attach Std Text Go to Effect
field & select relevant code of
Std Text
Insert Text popup screen
appears.
On Insert Text screen Flag
Expand immediately , enter Text
ID ST & click on dropdown of
Text Name field
Next Popup screen Database
selection for SAP script text
Execute Popup screen
Database selection for SAP
script text without entering any
data
87
88
89
90
1.
2.
3.
4.
5.
6.
7.
92
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
By Drill Down go to
selection screen
Equipment Category - M
Maintenance Plant
93
94
PMIN
Select Operations
Select
from Drill
Down
Select
from Drill
Down
Select
from Drill
Down
Select
from Drill
Down
95
PMEX
Select
from Drill
Down
96
97
Process of Selection of
Order, Execution of Order,
confirmation & TECO will be
similar to processes
explained in process
1. Preventive Maintenance
98
Report1. of Shutdown
Planning
Go to T. Code IW49N
Display order & Operation:
selection of order & Operation
screen appears
Flag Outstanding & In process
Order
Enter Order type
Enter Main work center
99
100
Report 2 of Shutdown
Planning (MATERIAL)
Go to IWBK Material
Availability Check (for orders)
Material availability Information
screen
Click Multiple Selection of Order
Field
Click Multiple selection button
102
103
1.
2.
3.
4.
5.
6.
7.
104
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
Execution of Orders
Confirmation of Orders
105
109
Creation of Measuring
Document
Go to T. Code IK11 - Crete
Measuring Document
Enter Measuring Point (as
selected)
Again Click on Enter Button
Enter MeasRdg as taken from
site
Again Click on Enter Button
A Massage Appears In case
Reading is Outside range
Again Click on Enter Button
Main screen of M8 type
Notification Generates
Automatically
110
111
Creation of Measuring
Document Thru Entry list
Go to T. Code IK34
Collective entry of
MeasDocuments: Initial screen
Enter Entry list number
Click on Enter Button
Collective entry of
MeasDocuments: overview
screen Appears
Enter measuring Reading in
relevant measuring point field
Click on Enter Button
A Massage Appears In case
Reading is Outside range &click
again enter button. M8
Notification will generate
A massage appears as xx
Measuring document Created
| Aug 18, 2015
Navigate>
SAP Screen
1.
2.
3.
4.
5.
6.
7.
113
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
Creation of M6 Notification
Manual Process
Go to T. Code IW21Create
Notification
Enter Notification Type
System Generated
114
115
Selection of M6 Notification
Go to T. Code IW28 Selection
of Notification
Flag check box Outstanding (as
reqd)
Enter Notification Date
Select Notification & Create
PM09 Type Order
Click Create button
of Order Tab
Navigate> SAP Screen
116
117
118
119
120
1.
2.
3.
4.
5.
6.
7.
121
Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration
Go to Operation TAB
Select Control Key As PMEX
122
123
124
Go To Change Mode of PR
(ME52N)
GO To Document Overview &
Select Relevant PR
GO TO Customer TAB & Enter
all Required Deatils
Save PR
Navigate> SAP Screen
125
126
127
128
STANDARD REPORTS
[MCI1]
129
STANDARD REPORTS
2. Manufacturer Analysis
[MCI2]
130
STANDARD REPORTS
3. Location Analysis
[MCI3]
STANDARD REPORTS
[MCI4]
132
STANDARD REPORTS
[MCI5]
133
STANDARD REPORTS
6. Object Statistics
[MCI6]
This report provide the detail about the object statistics ( like
how many Equipment installed on a Function Location)
Standard drill down (Key Figure)
Object class
Manufacturer
Material
Construction year
Month
134
STANDARD REPORTS
7. Breakdown Analysis
[MCI7]
135
STANDARD REPORTS
8. Cost Analysis
[MCI8]
136
STANDARD REPORTS
9. MTTR/MTBR Equipment
[MCJB]
137
STANDARD REPORTS
138
139
140
10
141
PLANT REPORTS
11
12
13
14
15
16
17
18
19
142
MINES REPORTS
20
21
22
23
24
25
26
27
Breakdown Summary
143
Select Equipment
Flag
Maximum Reading of
Counter
Press ICON
For Save
THE END
145
Select Equipment
Flag
Press ICON
Select Equipment
Press Icon
Press ICON
For Save
THE END
150
Counter should be
GREATER than
Previous Reading or
Difference not more
than 24 Hours
MAINTENANCE ITEM
WITH
TIME BASED PACKAGE
151
Continued..
Maintenance Strategy
Enter Equipment
Flag
Press Icon ,
Lists
Press Icon
for Save
MAINTENANCE ITEM
WITH
PERFORMANCE BASED PACKAGE
154
Maintenance Strategy
Enter Equipment
Flag
Press Button ,
Press Icon
Press Icon
for Save
157
IP01
Maintenance Category
Maintenance Strategy
Press Icon
Go to TAB
Press Icon
Flag
159
Press Icon
For Save
Press Icon
The End
160
Maintenance Category
Maintenance Strategy
Press Icon
Go to TAB
Press Icon
Flag
162
Press Icon
For Save
Press Icon
The End
163