00 SGG SAP training PM overview

SAP Plant Maintenance
Training SAP Overview


Agenda

1.

PM Organization Structure
1.1. Maintenance Plant & Maintenance Planning Plant
1.2. Maintenance Planner Group & Maintenance Work Center

2.

Technical Objects
2.1.
2.2.
2.3.
2.4.

3.

Functional Location
Equipment
Bill of Material
Measuring Point

Maintenance Processing
3.1. Breakdown/Corrective Maintenance
3.2. Preventive Maintenance
3.2. Refurbishment Order

4.

PM Information System

© 2009 Semen Gresik Group / Page 2


PM Organization Structure
Maintenance Plant :
 Is organizational unit where you can
manage technical objects and work center
Maintenance Plant

Maintenance Planning Plant :
 Is organizational units where task list,
material planning, maintenance plans are
managed, maintenance notification are
created and maintenance orders can be
handled

Maintenance Planning Plant

Maintenance Work Center
 Is a group persons who responsible to do
task
Planner Group
 Group of employees for the planning and
processing of maintenance tasks in a
particular plant

Planner Group
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Maintenance
Work Center


Maintenance Work Center
Work Center can be one of the following :


Machine



Group of machines



People



Group of people

In Plant Maintenance work centers are used as:
1.

Main work center in the master record for the equipment or functional

location

2.

Main work center in a maintenance planning

3.

Main work center in the task list header

4.

Main work center in the order header

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Functional Location

Functional Location

Functional location = multi-level, hierarchical structure,
Functional Location represents the place at which a maintenance task is to
organized according to ...
be performed

Spatial

Technical


Pieces of equipment can be installed &
dismantled at functional locations



Functional

The costs of maintenance task have to be
monitored for certain parts of your technical
system
 SAP AG 1999

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Criteria


Structure Indicator

Functional location = multi-level, hierarchical structure,
organized according to ...

Spatial

Technical

Structure Indicator
Functional

Criteria

Edit mask

Hierarchy levels

Location number

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 SAP AG 1999

AN-ANN-N-X-X

1 2 3 4 56

A1
A1-B
A1-B02
A1-B02- 9
A1-B02- 9-C
A1-B02- 9-C- 1

A = Alpha
N = Numeric
X = Alphanumeric

System
Area
Sub-area

Function
Sub-function
Item


Automatic Assignment Upon Creation
Automatic Assignment Upon Creation
C1
Clarification
plant

Existing
functional
locations

C1-M
Mechanical
cleaning
C1-M01
Sand trap

New
functional
locations

 SAP AG 1999
© 2009 Semen Gresik Group / Page 7

C1-B
Biological

cleaning
C1-M02
Oil/fat
trap

C1-M01-2
Ventilator
Ventilator

C1-B01
Pump
plant

C1-M02-2
Ventilator

C1-B01-1
Pump 1

C1-B02-2
Filter cell

C1-B02
Filtering
station


Equipment
A pieces of equipment is an individual physical
object that is to be maintained as an

autonomous unit
Equipment can be installed at functional
location
You should always create an equipment master record for a technical
object if:
1.

You need to manage individual data for the object

2.

Breakdown, prepared or preventive maintenance task are required for
an object and must be recorded

3.

The costs of maintenance tasks for this object are to be monitored

4.

You need to record the usage time of this object at functional location

5.

Technical data for this object must be collected and evaluated over
long periods of time

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Autonomous Equipment
Equipment
Autonomous

Equipment category:
Machine

Equipment category:
Fleet object
 SAP AG 1999
© 2009 Semen Gresik Group / Page 9

Equipment category:
Production resources and tools

Equipment category:
Test equipment


Autonomous Equipment Hierarchy
Autonomous Equipment Hierarchy

Level 0
Superior
Equipment:
Fleet object

Level 1
Sub-equipment:

Drive unit

Level 2
Sub-equipment:

Gears

Level 3
Sub-equipment:

Shaft

 SAP AG 1999

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Installation/Dismantling of Equipment

Installation/Dismantling of Equipment

You can monitor the installation times for a piece of equipment from
 SAP
AG 1999
both
the
functional location view and the equipment view

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Equipment
EquipmentUsage
Usage List
List
S-15

Usage list

03/01/ - 09/20/98

 SAP AG 1999

© 2009 Semen Gresik Group / Page 12

S-15


Equipment and Asset Accounting
Equipment
& Asset Accounting

Equipment master record

Location data

Asset number

Assets

 SAP AG 1999

To assign pieces of equipment to an asset, you can define
an asset number in the equipment master record

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Equipment & Material

Material master record

MATERIALS
MANAGEMENT

PLANT
MAINTENANCE

Uses for
Material Master
• Buy
• Sell
•Make (Produce)
•Stock Inventory
•Volume Tracking

Uses for
Equipment Masters

Material Master

X
20’ Truck
Serial No. Profile

Description:
MAN K4000
Stock quantity:
10 pcs

•

•

•History / Tracking
•Plant Maintenance
•. . . . . . .

•
Eq. A Material X
Serial No. 1234
Mfg. GM

C152 JTS

E631 VYA

Equipment
Eq. B Material X
Serial No. 5678
Mfg. Volvo

Eq. C

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Description:
HD-MR 999
Manufacturer:
MAN
Model:
K4000
Year of production:1991

•

Equipment and
material masters are
related.
If you want to stock
this part, it needs to
be in the material
master.
If you want to
maintain history on
this part, it needs an
equipment master.
The same item can
have both a material
master and an
equipment master.

Bill of Material in Plant Maintenance
Bills of Material in Plant Maintenance

Structuring
of object

Spare parts planning
in order

Technical object

Maintenance
bill of material
Spare parts planning
in task list
 SAP AG 1999

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Spare part Assembly (BOM)

Assembly Example
Fork Lift (Equipment)
Brake Assembly
Rotors
Calipers
Brake Pads
Motor Assembly (Stockable Assy.)

Exhaust Assembly
Tail Pipe
Exhaust Pipe
Muffler
Wheels
Tires
Seat
R

 SAP America

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Measuring Point

Measuring points
and counters

Technical objects

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Measuring Document

Meas . doc.

Meas . doc.
Temperature 60

°C

Meas . doc.
Pressure
58 pascals

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Meas . doc.
Operating hours
01275

Kilometers
2351


Breakdown/Corrective Maintenance Activity
Notification
Purchasing
Material
requisition

Maintenance
Order

Material Availability
Check

Operation

Activity

MO Released

PMIS

Material
Withdrawals
Warehouse
management
system

Goods Issue

MO Completion
MTTR
MTBR

Goods receipt

Notification
Closed

Stock
Distribution
Cost
Controlling
Accounting

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Notification structure

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Catalogs

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Maintenance Order

Order header

For example: Order type, dates, plant, main object,
priority, description

Object list

Equipment (assembly), functional locations,
maintenance notifications

Operation

For example: Work center, control key, description
standard time
Material list

Production resources/tools

Settlement rule

Costs
(estimated / planned / actual)

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For example: Material, quantity, storage location


Order Release

Effects of order release:

Reservation effective,
can be withdrawn
Papers can be printed
Confirmation possible
Goods movement possible

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Material Movement – Process Flow
Stock Material

Non Stock Material

Component

Component

assignment

assignment
Purchase
Material

requisition

reservation
Purchase
order

Order

Availability
check

release

May

Order
release
Printing

Automatic

availability
check

Goods
receipt
Company

May

xyz

Goods
issue

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Invoice

Invoice
receipt


Material
AvailabilityList
List
Material
Availability
Traffic Light:

Signifies:

All materials available for planned date

Green
Material available by latest date
Yellow
Material not available
Red

Goods receipt indicators:
Complete goods receipt
Goods receipt not made or incomplete

 SAP AG 1999

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