Presentation By:
Mr. Subhrajyoti Bhattacharjee
B.E., P.G.D.M., PMP®, Certified SAP PM Solution
Consultant
SAP Plant Maintenance
Brief Background of Presenter Subhra works as SAP Systems Analyst at Iluka
Resources Limited, Perth, Western Australia
He has a Net experience of around 7.8 years with around6 years of SAP Consulting Experience in SAP PM & CS,MM modules. He has also has standard configurationknowledge of SAP PS, DMS and integration aspects ofother SAP modules & applications
He has worked in multiple SAP Implementation, Upgrade,Support & Audit assignments in Australia, USA, India andMiddle East and is an ex-employee of PwC India Ltd,T.C.S. Limited
He also possesses Core Industry experience of 1.8 yearsin Maintenance & Inbound Logistics
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports
Organization
Government & Authorities
Customers
Environment
Vendors
Organizational ERP
System
Purchasin
g
Sales &
Distributio
n
Projects
Government & Authorities
Productio
n
Planning
Vendors
Customers
External Environment
Finance &
Controllin
g
HR &
Payroll
Maintena
nce
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports
Maintenance is a Support Function within an Organization and Maintenance
costs generally constitute a part of Production overhead costs except when
Maintenance is carried out on Customer Assets to earn revenue.
Primary Objective of Maintenance is to maintain a high level of Availability,
preventing degeneration and maintaining optimal utilization life of an
Organization’s Physical Assets.
Physical Assets primarily comprise:
Fixed assets such as Plant & Machinery, Buildings & Properties, Vehicles and
so on. Usually such assets have a Long useful life (usually > 1 year) over which
they are depreciated
Operating Assets which may not be treated as Assets in Financial Module nor
depreciated, but having a long term utilization
High valued current assets such as High valued spares/operating
supplies/machine parts which are subject to Refurbishments with their condition
based values maintained accurately
Key Performance objectives in Maintenance include
Maintaining a high level of OEE (Overall Equipment Effectiveness)
Maintaining and Optimal balance between Cost of Breakdown vs. Cost of
Prevention
Utilizing concepts such as TPM, RCM etc. to contribute in Lowering Operating
costs and minimize adverse effects on Equipment ,Operating resources and
Environment
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports
Company Code
Maintenance Planning
Plant
Maintenance Plant
Maintenance Plant
Maintenance Planning
Plant
Maintenance Plant
Centralized
Planning
De-centralized
Planning
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports
SAP PM:
Master Data
Technical Objects
Planning Objects
Others
Work Centres
Capacity information includes:
Unit of capacity
Start/End times
Utilizations
Shift schedules etc.
Capacity
PM Work Centre Category “0005”
Comprises: Basic data, Default values, Capacity view, Scheduling view, HR Assignments, Costing view
Work Centre
Work Centre
Hierarchy
Work Centre Hierarchy is a
Grouping of Work centres
comprising Maintenance Task
Force
Capacity Functionalities
Capacity Leveling
Capacity Planning
Load Monitoring
Functional Locations
Equipment
Sub Equipment
Equipment Bill of Material
Component material parts
Serial Number
Material No
Structured into Hierarchical
Levels using Structure
Indicators
Plan
Task List
Maintenance item
Bottom up
planning
Top Down
planning
Plans
• Single cycle Plans
• Strategy Based Plans
• Counter Based Plans (Single/Multi Counter)
Task Lists
• General Task Lists
• Functional Location Task Lists
• Equipment Task Lists
Items
• Standard items
• Strategy based items
Permits
Class/
Characteristics
Measuring Points/Counters
Other Master
Data
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports
Maintenance Notifications vs. Maintenance
Orders
Maintenance Notifications are Reporting objects to record:
Maintenance requirement
Cause, Object Impacted, Tasks due & Activities Performed
Types: Maintenance Request, Malfunction (Breakdown) Report, Activity Report, Service Notifications
Maintenance Notifications generally do not record Costs
Maintenance Orders are a complete record of:
Operations performed
Components used (Stock/Non stock)
Services hired
Time and costs posted
Settlements executed
Types: Breakdown Orders, Planned Orders, Predictive Orders, Calibrations Orders, Refurbishment Orders, Capital Work Orders
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Advanced scenarios, Interfaces & Reports
Order (Type
PM01) created
Convert to PM
Order?
Assigned permits if
any are issued by
relevant personnel
Is stock part
available?
Purchase
requisition created
(MM side)
Approved purchase
requisitions converted to
Purchase order
Yes
YesNo
Notification user
status changed to
ALWD and
notification
released
PM Oredr
Planning done
(Operation,
Components,
Service, Permits)
Order user status
changed to PLND
and order released
No
Stock part
Y
Issue stock part to Reservation No
assigned to PM Order
Master Data
Functional
LocationEquipment
Material
(Stock parts)
Permits (If
applicable)
Activity
Type
Equipment breaks
down
Shop papers
printed from
PM order
No
In SAP
Outside SAP
Service
Master record
Work center
(PM & PP)
Maintenance
Notification (Type
“M2”) created
Existing Notification
(Report IW29)?
No
Production personnel
follows up on work done
against existing
Notification
Yes
Yes
Is Stock part
planned?
No
Goods receipt to Storage
location
Is Non – stock
part planned?
Is Extenal
service
planned?
Purchase
requisition
created within
PM orderYes
Approved
purchase
requisitions
converted to
Purchase order
Goods receipt against PO
posts costs to associated
PM order
Purchase
requisition
created within
PM order
Approved
purchase
requisitions
converted to
Purchase order
Service acceptance
throughService entry
sheet against Service PO
posts costs to associated
PM order
Is Maintenance
work completed?
User status of
Maintenance order
changed to MTCO –
Completed by
Maintenance
Yes
Is further planning
required?
Yes
No
Production
personnel to
confirm Order
completion by
changing user
status to PRCO
Time confirmation
for Manhours with
suitable Activity
Type
Settlement rule defined in
order & Order Technically
completed with details of
Malfunction end date/time
Order settled to relevant
settlement receiver (Cost
Center)
Further work done is
recorded in
Notification&
Notification Tasks
Technically completed
No
SAP Notification mail to
designated Person
responsible in
Notification header
SAP Notification mail to
initiator of work
Scheduling overview
report generated by
maintenance
personnel on a
periodic basis
Assigned permits if
any are issued by
relevant personnel
Is stock part
available?
Purchase
requisition created
(MM side)
Approved purchase
requisitions converted to
Purchase order YesNo
Preventive
Maintenance order
(Type”PM02")
generated
Orders generated
for the periodare
planned further
(Operation,
Components,
Service, Permits)
Order user status
changed to PLND
and order released
No
Stock part
Y
Issue stock part to Reservation No
assigned to PM Order
Master Data
Functional
LocationEquipment
Material
(Stock parts)
Permits (If
applicable)Activity
Type
Yes
Shop papers
printed from
PM order
No
In SAP
Outside SAP
Maintenance
Task List
Work center
(PM & PP)
Is next call object –
Maintenance Order
due?
Yes
Is Stock part
planned?
No
Goods receipt to Storage
location
Is Non – stock
part planned?
Is Extenal
service
planned?
Purchase
requisition
created within
PM orderYes
Approved
purchase
requisitions
converted to
Purchase order
Goods receipt against PO
posts costs to associated
PM order
Purchase
requisition
created within
PM order
Approved
purchase
requisitions
converted to
Purchase order
Service acceptance
throughService entry
sheet against Service PO
posts costs to associated
PM order
Is Maintenance
work completed?
User status of
Maintenance order
changed to MTCO –
Completed by
Maintenance
Yes
Is further planning
required?
Yes
No
Production
personnel to
confirm Order
completion by
changing user
status to PRCO
Time confirmation
for Manhours with
suitable Activity
Type
Settlement rule defined in
order & Order Technically
completed with details of
Start/end date/time
Order settled to relevant
settlement receiver (Cost
Center)
Service
Master record
Maintenance
Plan
Counter (For
counter based
plans)
Maintenance Task
List created
Maintenance Plan
created (Single
cycle/Strategy
based/Counter
based)
Maintenance plan
scheduled
(Background job/
Manual)
Measurement
document posting
for Counter Based
plans
Planned Due
dates for order
creation are set in
system
Scheduling overview
report generated by
maintenance
personnel on a
periodic basis
Is stock part
available?
Purchase
requisition created
(MM side)
Approved purchase
requisitions converted to
Purchase order YesNo
Preventive
Maintenance order
(Type”PM02")
generated
Calibration Orders auto
generated and released
(Operation,
Components, Service,
Permits)
No
Stock part
Y
Issue stock part to Reservation No
assigned to PM Order
Master Data
Functional
LocationEquipment
Material
(Stock parts)
Permits (If
applicable)Activity
Type
Yes
Shop papers
printed from
PM order
No
In SAP
Outside SAP
Maintenance
Task List
Work center
(PM & PP)
Is next call object –
Maintenance Order
due?
Yes
Is Stock part
planned?
No
Goods receipt to Storage
location
Is Non – stock
part planned?
Is Extenal
service
planned?
Purchase
requisition
created within
PM orderYes
Approved
purchase
requisitions
converted to
Purchase order
Goods receipt against PO
posts costs to associated
PM order
Purchase
requisition
created within
PM order
Approved
purchase
requisitions
converted to
Purchase order
Service acceptance
throughService entry
sheet against Service PO
posts costs to associated
PM order
Is Maintenance
work completed?Yes
Is further planning
required?
Yes
No
Time confirmation
for Internal
Manhours with
suitable Activity
Type
Settlement rule set in
Calibration order
Service
Master record
Maintenance
Plan
Counter (For
counter based
plans)
Maintenance Task
List created
(Inspection point
300, MIC’s
entered)
Maintenance Plan
created (Single
cycle/Strategy
based/Counter
based)
Maintenance plan
scheduled
(Background job/
Manual)
Measurement
document posting
for Counter Based
plans
Planned Due
dates for order
creation are set in
system
Quality Inspection Lot
Generated
Result recording done
against Inspection Lot, Order
Technically completed
Order settled to relevant
settlement receiver (Quality
Cost Center)
Order (Type
PM01) created
Convert to PM
Order?
Assigned permits if
any are issued by
relevant personnel
Is stock part
available?
Purchase
requisition created
(MM side)
Approved purchase
requisitions converted to
Purchase order
Yes
YesNo
Notification user
status changed to
ALWD and
notification
released
PM Oredr
Planning done
(Operation,
Components,
Service, Permits)
Order user status
changed to PLND
and order released
No
Stock part
Y
Issue stock part to Reservation No
assigned to PM Order
Master Data
Functional
LocationEquipment
Material
(Stock parts)
Permits (If
applicable)
Activity
Type
Scope for correction/
predictive maintenance
identified by Operator/
Maintenance person
Shop papers
printed from
PM order
No
In SAP
Outside SAP
Service
Master record
Work center
(PM & PP)
Maintenance
Notification (Type
“M1” Maintenance
request) created
Existing Notification
(Report IW29)?
No
Requestor checks on work
progress
Yes
Yes
Is Stock part
planned?
No
Goods receipt to Storage
location
Is Non – stock
part planned?
Is Extenal
service
planned?
Purchase
requisition
created within
PM orderYes
Approved
purchase
requisitions
converted to
Purchase order
Goods receipt against PO
posts costs to associated
PM order
Purchase
requisition
created within
PM order
Approved
purchase
requisitions
converted to
Purchase order
Service acceptance
throughService entry
sheet against Service PO
posts costs to associated
PM order
Is Maintenance
work completed?
User status of
Maintenance order
changed to MTCO –
Completed by
Maintenance
Yes
Is further planning
required?
Yes
No
Production
personnel to
confirm Order
completion by
changing user
status to PRCO
Time confirmation
for Manhours with
suitable Activity
Type
Settlement rule defined in
order & Order Technically
completed with details of
Start/ end date/time
Order settled to relevant
settlement receiver (Cost
Center)
SAP Notification mail to
initiator of work
Work detailed in
Notification and Tasks
Technically completed
SAP Notification mail to
designated Person
responsible in
Notification header
No
Capital work Order (Type
“PM06”) created – with
relevant Maintenance
Activity type assigned
Assigned permits if
any are issued by
relevant personnel
Is stock part
available?
Purchase
requisition created
(MM side)
Approved purchase
requisitions converted to
Purchase order YesNo
Order Planning
done (Operation,
Components,
Service, Permits),
Settlement rule
defined
Capital order
released
No
Stock part
Y
Issue stock part to Reservation No
assigned to PM Order
Master Data
Functional
Location
Asset Master –
AuC/FxA (As
relevant)
Material
(Stock parts)
Permits (If
applicable)
Activity
Type
Shop papers
printed from
PM order
No
In SAP
Outside SAP
Service
Master record
Work center
(PM & PP)
Yes
Is Stock part
planned?
No
Goods receipt to Storage
location
Is Non – stock
part planned?
Is Extenal
service
planned?
Purchase
requisition
created within
PM orderYes
Approved
purchase
requisitions
converted to
Purchase order
Goods receipt against PO
posts costs to associated
PM order
Purchase
requisition
created within
PM order
Approved
purchase
requisitions
converted to
Purchase order
Yes
Service acceptance
throughService entry
sheet against Service PO
posts costs to associated
PM order
Is Maintenance
work completed?Yes
Is further planning
required?
Yes
No
Time confirmation
for Manhours with
suitable Activity
Type
Periodic settlement
executed to relevant
receiver (AuC/FxA)
Asset under
construction created
by Business SAP
Finance Team
Maintenance Team
intimated on the AuC
Number
Capital work –
New asset build up
or Enhancement
New Asset buildup
Existing Equipment No (with
assigned Fixed asset) would
be identified
Asset Enhancement
Functional Location (for asset
build up created) as reference
Technical object
Equipment
(Associated to
FxA)
On completion of work Order
Technically completed with
necessary details
In case of Asset buildup work,
Finance finally settles AuC to
a FxA ( created)
Maintenance Team
intimated on the FxA
Number
Functional Location Structure
completed with assigned
Equipment tagged to FxA
number
Refurbishment order type
“PM04" created for Material
No, to convert from C3 -
Damaged to C2 -
Refurbished state
Purchase
requisition created
(MM side)
Approved purchase
requisitions converted to
Purchase order Yes
Order Planning done
(Operation – Internal or
External Services, Additional
Components if any),
Settlement rule defined
No
Stock part
Y
Issue stock part to Reservation No
assigned to PM Order
Master Data
Serial
NumberEquipment
Activity
Type Shop papers
printed from
PM order
No
In SAP
Outside SAP
Service
Master record
PM Work center
(For Internal
Refurbishment)
Additional
Stock parts
required/
planned?
No
Goods receipt to Storage
location
Is Non – stock
part planned?
Is Extenal
Refurbishment
service
planned?
Purchase
requisition
created within
PM orderYes
Approved
purchase
requisitions
converted to
Purchase order
Goods receipt against PO
posts costs to associated
PM order
Purchase
requisition
created within
PM order
Approved
purchase
requisitions
converted to
Purchase order
Service acceptance
throughService entry
sheet against Service PO
posts costs to associated
PM order
Is Maintenance
work completed?Yes
Is further planning
required?
Yes
No
Time confirmation
for Manhours with
suitable Activity
Type – In case of
internal manhour
consumed
Goods receipt of
Refurbished part (val. Type
“C2") to store
Need for Refurbishment
identified
Asset No
(Tagged to
Equipment ID)
On completion of work Order
Technically completed with
necessary details
Settlement executed to settle
order costs (As per business
requirement to FxA)
Ref. Material (with
valuation types
C1, C2, C3)
Batch Numbers for C1,
C2, C3 states of Ref
material
Damaged Material part
(valuation type C3) issued to
reservation no. in order
Order releasedAvailable in
stock?No
Yes
ERP Systems: An Overview
Plant Maintenance: An Overview
Organizational Structure
Master Data in SAP PM
Maintenance Processing: Objects
Maintenance Processing: Scenarios
Integrations, Advanced scenarios, Interfaces & Reports
Equipment
Functional
Location
Fixed
Asset
BOM SparesPP Work
Center -
Machine
Plant Maintenance
Financial
Accounting
PM Work
Center
Order
Header
Operation
- Internal
Compone
nt
Operation
– Services
Shutdown
Notification
Maintenance
Plan
CostsMaterial Master
Service Master
Material Management
Controlling
Activity
Types
Sender Cost
Center
Receiver
Cost Center
QM Master
Equipments
Employe
e
Planned
Rates /hr
G/L
Account
PM - Customer Service Scenarios
PM - Work Clearance Management
PM – Fleet Management
PM – Mobile Asset Management
** PM – Project Oriented Maintenance
** PM – Linear Asset Management
** PM – Rotables Subcontracting
** PM – Inspection Rounds
** PM – Take over- Hand over of Equipments
** Functionalities available only in ECC 6.0 and in specific EHP versions
SAP Plant Maintenance
SCADA
SAP MI
SAP
BW
Others
Maintenance Cost Analysis Report
Wave- I
Wave- II
Man hour Utilization Report
Wave- I
Wave- II
Downtime Analysis Report
Wave- I
Wave- II
MTTR/MTBF Report
Wave- I
Wave- II
Cause and Effect Analysis Report
Wave- I
Wave- II
Preventive Schedule Overview Report
Wave- I
Wave- II
Material Goods Movement/Consumption Report
Wave- I
Wave- II
Thank you !!