Anda di halaman 1dari 78

ASAP Implementation Methodology

Business Process Blueprint

Health Water Bottling CO Ltd.

Plant Maintenance Business Process Blueprint Document


Submitted by:
Hazem Mohsen

Internal and confidential document.


Business Blueprint
PM – Plant Maintenance

PROJECT IDENTIFICATION

Project Name Project Type


(CBI, Implementation, CSS, Upgrade, Internal, other)
NOVA Implementation
Customer Name
HWB – Health Water Bottling CO. Ltd
NOVA Project Sponsor NOVA Project Manager
Ayman Abushawish
ARETE Project Sponsor ARETE Project Manager
Muhammad Abuelainen

Author Document Location (repository/path/name)


Hazem Mohsen
Version Status Date (YYYY-MM-DD) Document
Classification
2.0 Updated 05.03.2014 Confidential
REVISION HISTORY

Version Date Description


1.0 25.02.2014 Creation
2.0 05.03.2014 Modification

Business Process Blueprint Plant Maintenance Version 1.0 Page 2 of 78


Business Blueprint
PM – Plant Maintenance

REVIEW AND APPROVAL

Name: Date ( )
Title:

Name: Date ( )
Title:

Name: Date ( )
Title:

Business Process Blueprint Plant Maintenance Version 1.0 Page 3 of 78


Business Blueprint
PM – Plant Maintenance

Contents
1 Executive Summary .............................................................................................................................................. 9
1.1 Business Process Master List ....................................................................................................................... 9
2 SAP Organizational Structure .............................................................................................................................10
2.1 Company Code ...........................................................................................................................................10
2.2 Plant ...........................................................................................................................................................10
2.3 Maintenance Planning Plant ......................................................................................................................11
2.4 Maintenance Planner Groups ....................................................................................................................11
3 Master Data .......................................................................................................................................................13
General Process Description ...................................................................................................................................13
3.1 Functional Location ....................................................................................................................................14
3.1.1 High Level System Realization Concept .............................................................................................14
3.1.2 Configuration Considerations ............................................................................................................15
3.1.3 Number Range ...................................................................................................................................15
3.1.4 Reports ...............................................................................................................................................16
3.1.5 Integration Points...............................................................................................................................17
3.2 Equipment ..................................................................................................................................................18
3.2.1 High Level System Realization Concept .............................................................................................18
3.2.2 Configuration Considerations ............................................................................................................19
3.2.3 Number Range ...................................................................................................................................20
3.2.4 Reports ...............................................................................................................................................21
3.2.5 Integration Points...............................................................................................................................21
3.3 Fleet Objects ..............................................................................................................................................22
3.3.1 High Level System Realization Concept .............................................................................................22
3.3.2 Configuration Considerations ............................................................................................................22
3.3.3 Number Range ...................................................................................................................................23
3.3.4 Reports ...............................................................................................................................................23
3.3.5 Integration Points...............................................................................................................................24
3.4 Installation and Dismantling ......................................................................................................................25
3.4.1 High Level System Realization Concept .............................................................................................25
3.4.2 Process Flow:......................................................................................................................................26
3.4.3 Assumptions .......................................................................................................................................26
3.4.4 Reports ...............................................................................................................................................27

Business Process Blueprint Plant Maintenance Version 1.0 Page 4 of 78


Business Blueprint
PM – Plant Maintenance
3.4.5 Integration Points...............................................................................................................................27
3.5 Bill of Material ............................................................................................................................................28
3.5.1 High Level System Realization Concept .............................................................................................28
3.5.2 Configuration Considerations ............................................................................................................29
3.5.3 Number Range ...................................................................................................................................29
3.5.4 Integration Points...............................................................................................................................29
3.6 Permits .......................................................................................................................................................30
3.6.1 High Level System Realization Concept .............................................................................................30
3.6.2 Organizational Implications / Considerations ....................................................................................30
3.6.3 Configuration Considerations ............................................................................................................31
3.6.4 Number Range ...................................................................................................................................31
3.6.5 Reports ...............................................................................................................................................31
3.6.6 Integration Points...............................................................................................................................31
3.7 Work Centers .............................................................................................................................................32
3.7.1 High Level System Realization Concept .............................................................................................32
3.7.2 Configuration Considerations ............................................................................................................34
3.7.3 Number Range ...................................................................................................................................34
3.7.4 Reports ...............................................................................................................................................34
3.7.5 Integration Points...............................................................................................................................34
3.8 Characteristics ............................................................................................................................................35
3.8.1 High Level System Realization Concept .............................................................................................35
3.8.2 Configuration Considerations ............................................................................................................36
3.8.3 Number Range ...................................................................................................................................36
3.8.4 Reports ...............................................................................................................................................36
3.8.5 Integration Points...............................................................................................................................37
3.9 Classes ........................................................................................................................................................38
3.9.1 High Level System Realization Concept .............................................................................................38
3.9.2 Configuration Considerations ............................................................................................................39
3.9.3 Number Range ...................................................................................................................................39
3.9.4 Reports ...............................................................................................................................................39
3.9.5 Integration Points...............................................................................................................................39
3.10 Measuring Points and Counters .................................................................................................................40
3.10.1 High Level System Realization Concept .............................................................................................40

Business Process Blueprint Plant Maintenance Version 1.0 Page 5 of 78


Business Blueprint
PM – Plant Maintenance
3.10.2 Configuration Considerations ............................................................................................................41
3.10.3 Number Range ...................................................................................................................................41
3.10.4 Reports ...............................................................................................................................................41
3.10.5 Integration Points...............................................................................................................................42
3.11 Catalogues..................................................................................................................................................43
3.11.1 High Level System Realization Concept .............................................................................................43
3.11.2 Configuration Considerations ............................................................................................................44
3.11.3 Number Range ...................................................................................................................................44
3.11.4 Reports ...............................................................................................................................................44
3.11.5 Integration Points...............................................................................................................................44
3.12 Task List ......................................................................................................................................................45
3.12.1 High Level System Realization Concept .............................................................................................45
3.12.2 Configuration Considerations ............................................................................................................47
3.12.3 Number Range ...................................................................................................................................47
3.12.4 Reports ...............................................................................................................................................47
3.12.5 Integration Points...............................................................................................................................47
3.13 Maintenance Strategy ................................................................................................................................48
3.13.1 High Level System Realization Concept .............................................................................................48
3.13.2 Configuration Considerations ............................................................................................................49
3.13.3 Number Range ...................................................................................................................................49
3.13.4 Reports ...............................................................................................................................................49
3.13.5 Integration Points...............................................................................................................................49
4 Corrective Maintenance (929) ...........................................................................................................................50
4.1 Business Process Diagrams ........................................................................................................................50
4.2 Business Process Description .....................................................................................................................51
4.3 Process Step Detailed Requirements & Solution .......................................................................................51
4.4 Key Policies/Operational Decisions or Logic within the Process ...............................................................54
4.5 Integration Points ......................................................................................................................................54
4.6 Potential Future Process Improvements (out of scope for this implementation).....................................54
4.7 Organization Structure Considerations......................................................................................................54
4.8 Master Data Considerations (including all relevant data relationships) ...................................................55
4.9 System Configuration Considerations........................................................................................................55
4.10 Reporting (operational and analytical) ......................................................................................................56

Business Process Blueprint Plant Maintenance Version 1.0 Page 6 of 78


Business Blueprint
PM – Plant Maintenance
4.11 Interfaces ...................................................................................................................................................56
4.12 Enhancements............................................................................................................................................56
4.13 Output (e.g. forms) ....................................................................................................................................56
4.14 Authorization .............................................................................................................................................57
4.15 Change Impact Summary ...........................................................................................................................57
5 Preventive Maintenance (930) ..........................................................................................................................58
5.1 Business Process Diagrams ........................................................................................................................58
5.2 Business Process Description .....................................................................................................................60
5.3 Process Step Detailed Requirements & Solution .......................................................................................61
5.4 Key Policies/Operational Decisions or Logic within the Process ...............................................................63
5.5 Integration Points ......................................................................................................................................63
5.6 Potential Future Process Improvements (out of scope for this implementation).....................................64
5.7 Organization Structure Considerations......................................................................................................64
5.8 Master Data Considerations (including all relevant data relationships) ...................................................64
5.9 Configuration Considerations ....................................................................................................................64
5.10 Reporting (operational and analytical) ......................................................................................................65
5.11 Interfaces ...................................................................................................................................................65
5.12 Enhancements............................................................................................................................................65
5.13 Output (e.g. forms) ....................................................................................................................................65
5.14 Authorization .............................................................................................................................................66
5.15 Change Impact Summary ...........................................................................................................................66
6 Spare Parts Refurbishment (887) .......................................................................................................................67
6.1 Business Process Diagrams ........................................................................................................................67
6.2 Business Process Description .....................................................................................................................68
6.3 Process Step Detailed Requirements & Solution .......................................................................................68
6.4 Key Policies/Operational Decisions or Logic within the Process ...............................................................69
6.5 Integration Points ......................................................................................................................................70
6.6 Potential Future Process Improvements (out of scope for this implementation).....................................70
6.7 Organization Structure Considerations......................................................................................................70
6.8 Master Data Considerations (including all relevant data relationships) ...................................................70
6.9 System Configuration Considerations........................................................................................................70
6.10 Reporting (operational and analytical) ......................................................................................................71
6.11 Interfaces ...................................................................................................................................................71

Business Process Blueprint Plant Maintenance Version 1.0 Page 7 of 78


Business Blueprint
PM – Plant Maintenance
6.12 Enhancements............................................................................................................................................71
6.13 Output (e.g. forms) ....................................................................................................................................71
6.14 Authorization .............................................................................................................................................72
6.15 Change Impact Summary ...........................................................................................................................72
7 Spare Parts Refurbishment via Subcontracting (ZPM1).....................................................................................73
7.1 Business Process Diagrams ........................................................................................................................73
7.2 Business Process Description .....................................................................................................................74
7.3 Process Step Detailed Requirements & Solution .......................................................................................74
7.4 Key Policies/Operational Decisions or Logic within the Process ...............................................................76
7.5 Integration Points ......................................................................................................................................76
7.6 Potential Future Process Improvements (out of scope for this implementation).....................................76
7.7 Organization Structure Considerations......................................................................................................76
7.8 Master Data Considerations (including all relevant data relationships) ...................................................77
7.9 System Configuration Considerations........................................................................................................77
7.10 Reporting (operational and analytical) ......................................................................................................77
7.11 Interfaces ...................................................................................................................................................77
7.12 Enhancements............................................................................................................................................77
7.13 Output (e.g. forms) ....................................................................................................................................78
7.14 Authorization .............................................................................................................................................78
7.15 Change Impact Summary ...........................................................................................................................78

Business Process Blueprint Plant Maintenance Version 1.0 Page 8 of 78


Business Blueprint
PM – Plant Maintenance

1 Executive Summary
This document is the result of detailed study of Business Process Requirements of Health Water Bottling
Company. All the processes mentioned here will be available and can be tested during Realization
phase.

1.1 Business Process Master List


The table below provides a complete list for all the processes will be implemented as well as the
requirements covers. In the following sections each process will be described in detail.

Business Process Master List


Process
Process Name Requirements Number(s)
Number
929 Operational Maintenance
930 Preventive Maintenance
887 Spare Parts Refurbishment
ZPM1 Spare Parts Refurbishment via subcontracting

Business Process Blueprint Plant Maintenance Version 1.0 Page 9 of 78


Business Blueprint
PM – Plant Maintenance

2 SAP Organizational Structure

ORGANIZATIONAL STRUCTURE
ID Relevant Corresponding Explanation if necessary
Organizational unit organization
SAP (Customer…)
Company code Finance & Accounting Independent Legal Entity
Company

Plant Region, branches, and


show rooms

Planning Plant A maintenance planning plant is the


organizational unit in which
maintenance
requirements are planned
Planner Groups Planner Groups represents Person
or group of people who plans
maintenance tasks

2.1 Company Code


Smallest organizational unit of external accounting for which a complete, self-contained set of accounts
can be created. This includes the entry of all transactions that must be posted and the creation of all
items for legal individual financial statements, such as the balance sheet and the profit and loss
statement.

o Health Water Bottling CO Ltd.


Naming Convention
o Refer to FI blueprint

2.2 Plant
The plant is one of the most important organizational units. It usually represents a production unit of a
company.
The plant, at which the operational systems of a company are installed, is called the maintenance plant.
If the maintenance work is planned at this plant, Locations subdivide a maintenance plant according to
location-based
Criteria, for example, site, building, coordinates.
Global Design Decisions
Health Water Bottling CO Ltd has the following Maintenance Plants

1000 NOVA Water Production Plant


1001 Riyadh - Sulay
1002 Vehicle Workshop
1003 Medina
1004 Jizan
Business Process Blueprint Plant Maintenance Version 1.0 Page 10 of 78
Business Blueprint
PM – Plant Maintenance
1005 Khamis
1006 Jeddah
1007 Dammam
1008 Riyadh
Naming Convention
A maintenance plant is defined in the system by means of a four-character alphanumeric key that is
unique in the client Health Water Bottling CO maintenance plant are as below:

1000 NOVA Water Production Plant


1001 Riyadh - Sulay
1002 Vehicle Workshop
1003 Medina
1004 Jizan
1005 Khamis
1006 Jeddah
1007 Dammam
1008 Riyadh

2.3 Maintenance Planning Plant


A maintenance planning plant is the organizational unit in which maintenance requirements are planned.
These requirements can either come from your own plant or from another maintenance plant assigned
to this maintenance planning plant.
The planners within a maintenance planning plant are defined by maintenance planner groups.

Global Design Decisions


Plant-specific planning: Maintenance plant = planning plant. In HWB organizational structures,
maintenance measures are planned in the same plant where the maintenance requirement occurs, the
maintenance orders are executed by workshops from the same plant, and the spare parts are stored in
the same plant
Naming Convention
A planning plant is defined in the system by means of a four-character alphanumeric key that is unique
in the client. Naming Convention for Plants with step 1001 (1002, 1003 …). There are only 2 Planning
Plants:

1000 NOVA Water Production Plant


1002 Vehicle Workshop

2.4 Maintenance Planner Groups


NOVA Water Production Plant Planner Groups are:
 100 Mechanical Group
 200 Electrical Group
 300 Blow Molding & Injection
 400 General Repair Group
 500 ACs

Business Process Blueprint Plant Maintenance Version 1.0 Page 11 of 78


Business Blueprint
PM – Plant Maintenance
Vehicle Workshop Planner Groups are:
 600 Vehicles

Naming Convention
Planner Group is defined in the system by means of an three character alphanumeric key.

NOVA Water Production Plant Planner Groups are:


 100 Mechanical Group.
 200 Electrical Group.
 300 Blow Moulding & Injection.
 400 General Repair Group.
 500 ACs.

Vehicle Workshop Planner Groups are:


 600 Vehicles

Business Process Blueprint Plant Maintenance Version 1.0 Page 12 of 78


Business Blueprint
PM – Plant Maintenance

3 Master Data
General Process Description

Master data contains information that is needed again and again in the same way.
These master data records are utilized within transactions, such as notifications and work orders,
throughout the maintenance process. Master data records need to be complete and accurate to
receive maximum benefits from the implementation. These benefits include detailed reports for
costing, labour usage, and maintenance activity scheduling.
In HWB, Master Data objects that are needed to serve maintenance processes are:
1- Functional Locations
2- Equipments
3- Installation and dismantling of equipments
4- Fleet Objects
5- Bill of Material
6- Permits
7- Work Centres
8- Classes
9- Characteristics
10- Measuring Points & Counters
11- Catalogues
12- Task List
13- Maintenance strategy
The purpose of Master Data is to ensure that:
o The time required for managing the technical objects is reduced.
o Maintenance processing and service processing is simplified.
o The time spent entering data during maintenance processing is reduced considerably.
o More specific, thorough and faster evaluation of maintenance and service data.

Business Process Blueprint Plant Maintenance Version 1.0 Page 13 of 78


Business Blueprint
PM – Plant Maintenance

3.1 Functional Location

Functional location is one of the most important master data objects in plant maintenance,
Functional locations are physical objects that are in a hierarchical structure and represent where
work is performed. The hierarchical structure allows maintenance activities to be performed,
tracked, cost allocated, and reported on at any level. Reporting can be detailed to one element in
the structure or as broad as necessary for the type of report required.
The aim of creating a functional location is to structure a technical system or building into units
that are relevant for Plant Maintenance.
Functional locations are used to represent the structures of the technical systems in HWB
according to functional criteria, to track all maintenance and Service tasks performed for an
individual area, to monitor the cost of maintenance and Service tasks and to analyze all usage
conditions that affect a certain area
The following sections will describe in detail:
 What is Functional Location and what is its use?
 How Functional Locations are mapped in HWB?
 Process flow of creation or change of Functional Locations

3.1.1 High Level System Realization Concept

Functional locations are physical objects that are in a hierarchical structure and represent where
work is performed. The hierarchical structure allows maintenance activities to be performed, tracked,
cost allocated, and reported on at any level. Reporting can be detailed to one element in the
structure or as broad as necessary for the type of report required. This hierarchical structure is
defined in SAP by a structure indicator.

Structure Indicator: The structure indicator of a functional location determines the structure of the
functional location label. It establishes the following factor:
 Number of hierarchy levels of a technical system
 Key length of the levels
 Separators (hyphens)
The structure indicator consists of two input fields:
 Coding template
 Hierarchy levels
The coding template is used to control which characters may be used for identification (letters,
numbers, or both) and how these characters are grouped together or split.
The hierarchy levels are used to define which level ends at which character and how many hierarchy
levels the structure may contain.

Business Process Blueprint Plant Maintenance Version 1.0 Page 14 of 78


Business Blueprint
PM – Plant Maintenance
A functional location can be identified using a maximum of 40 characters (= maximum length of the
coding template).

Structure Indicator is used to:


 Specify and monitor the generic structure of the functional location label
 Portray the hierarchy levels within the functional location structure in the functional location
label
 Make use of the system's automatic functions for generating the structure when you create
functional locations
The generic structure of the location label enables the system to determine a superior functional
location and to copy specific data from it into the new functional location. However, this is only
possible if the functional locations have been created strictly according to the top-down principle, in
other words starting with the uppermost functional location.

The following applies to functional location master records:


 Each functional location is defined and managed in the Plant Maintenance in a separate
master record.
 The labels for functional locations are structured hierarchically. The structure is specified
according to HWB criteria
 Each hierarchy level of the functional location labels represents a given level of detail in the
description of the system
The master record for the functional location uses the following views:
 General: General Data (Description, Status, Class, Type, Category, Reference Data and
Manufacturer Data)
 Location: Maintenance Plant , Location , Plant Section , ABC Indicator , Address
 Organization: Account assignment (company code, cost center), responsibilities
(maintenance planning plant , planner group)
 Structure: For example, structure indicator, higher-level functional location, installed
equipment

3.1.2 Configuration Considerations

When you create a functional location you have to select the category for functional location you are
creating.
Functional location category lets you differentiate functional locations according to how they are used.
Functional Location Categories to be used in HWB
o Technical System M

All functional location categories will allow installation of equipment

3.1.3 Number Range


The identification for functional locations is created using the structure indicator.

Business Process Blueprint Plant Maintenance Version 1.0 Page 15 of 78


Business Blueprint
PM – Plant Maintenance
The structure indicator consists of two input fields:
o Coding template
o Hierarchy levels

The coding template is used to control which characters may be used for identification (letters, numbers,
or both) and how these characters are grouped together or split. The hierarchy levels are used to define
which level ends at which character and how many hierarchy levels the structure may contain.
A functional location can be identified using a maximum of 40 characters (maximum length of the coding
template).

For HWB, it has been determined that One structure indicators will be used. The structure indicator
for HWB is comprised of eight levels.

The structure indicator for HWB will be in the form: XXX-NNNN-XXXXXX.


1 2 3

Level 1: HWB.
Level 2: Plant (1000, 1001 …).
Level 3: the location where the equipments are installed (like Production lines)

3.1.4 Reports

Report Name Transaction Description


Functional Location IL07 This report outputs a multi - level list of functional
List (Multilevel) locations. You can use a multi - level location list to
search for a location whose label you do not know
With multi - level lists there are possible filtering criteria
for the search. You can change the filter criteria as
required and the results will be displayed depending on
the selected filters.
Functional Location IH01 As an output for this report, the hierarchy of the
Structural Display functional location specified will be displayed.
You can display the following data by setting the
appropriate parameters:
The equipment installed at the functional locations
The hierarchies below the equipment
The BOMs that belong to the equipment (multi - level
explosion)
You can define the fields that are to be displayed using
the function for the settings. The system will save the
selection, so you will see exactly the same fields when
you next call up the list.
If you would prefer to see a graphic display of the
hierarchy, you can call one up using the appropriate
menu option in the "Goto" menu.

Business Process Blueprint Plant Maintenance Version 1.0 Page 16 of 78


Business Blueprint
PM – Plant Maintenance
3.1.5 Integration Points

No Description Module
1 Assigning Account Assignment information to Functional Controlling (CO)
Location

Business Process Blueprint Plant Maintenance Version 1.0 Page 17 of 78


Business Blueprint
PM – Plant Maintenance

3.2 Equipment
 A piece of equipment is an individual physical object that is to be maintained
 Pieces of equipment usually represent single objects, for which maintenance tasks should be
performed and recorded.
 Equipment can be installed at functional locations.
 A piece of equipment can be linked with a material (if the equipment can be stored in storage
location).
 Production machines, and all supported machines will be treated as equipment
 Following sections will describe the following in detail:
 What is Equipment and what is its use?
 Types of Equipments in HWB.
 Process flow of creation or change of Equipments.

3.2.1 High Level System Realization Concept

Equipment is an individual physical object that is to be maintained as an autonomous unit.


Equipment usually represents a single object, for which maintenance tasks should be performed
and recorded.
Equipment is managed independently in the system, so that you can:
 Manage individual data from a maintenance perspective for the object (for example,
cost center, object description, usage, serial number, model number, manufacturer ,
year of construction, warranty period, usage sites, etc.)
 Perform individual maintenance tasks for the object either regular, planned or
resulting from damage
 Keep a record of the maintenance tasks performed for the object
 Collect and evaluate technical data over a long period of time for the object
 The costs of maintenance tasks are to be monitored for the object
 Records of usage times at superior equipments are required for the object
The system manages the master records for equipments at client level. This means
that their numbers are valid for the entire corporate group

The equipment master record uses the following views in the standard system:

 General:

It contains fixed data, which generally does not change in the course of time, for
example, the object type, the acquisition value of the equipment, its size and
dimensions, the year of construction and the manufacturer data.

 Location:

Business Process Blueprint Plant Maintenance Version 1.0 Page 18 of 78


Business Blueprint
PM – Plant Maintenance
It contains data about the location of the equipment, for example, Maintenance Plant,
Location, Plant Section, ABC Indicator, and Address

 Organization:

Account assignment (for example, company code, cost center, asset number),
responsibilities (for example, maintenance planning plant, planner group, main work
center)

 Structure:

For example, structure indicator, higher-level functional location, superior equipment

 Serial Number Data:

This data is specified to manage equipment not only as individual object, but also
from an inventory management perspective. This data comprises material data as
well as stock
Equipment will be defined as a Material Item in the Material Management with a serial
number profile, and it will be activated from the Plant Maintenance Module as
Equipment, so any movement between the warehouse and the site will influence the
stock balance from this component by adding or issuing

3.2.2 Configuration Considerations

There is a Key for distinguishing individual technical objects according to their use; this key is
called Equipment Category

Structuring is performed using the Equipment Category (for example, machines, fleet
objects, and Tools).
Equipment will be grouped by using Object Type which is used to divide of a technical object
for precise description and can be searched and listed accordingly.

IN HWB:
Equipment Category: M Machines

Object types:
- PRD01: BlowMoulding Machine.
- PRD02: Air Veyor.
- PRD03: Rinser Machine.
- PRD04: Filler Machine.
- PRD05: Bottle Rejector.
- PRD06: Mechanical Conveyor.
- PRD07: Labelling Machine.
- PRD08: Printer.
- PRD09: Carton Erector.
Business Process Blueprint Plant Maintenance Version 1.0 Page 19 of 78
Business Blueprint
PM – Plant Maintenance
- PRD10: Carton Printer
- PRD11: Palletizer Machine.
- PRD12: Plastic Wrapping.
- PRD13: Handle Applicator.
- PRD14: Injection/Blowing.
- PRD15: Date Printer.
- PRD16: Induction Sealer.
- PRD17: Stretch Wrapper
- PRD18: Depallatizing Machine.
- PRD19: Caps Feeder.
- INJ01 : Injection Machine.
- INJ02 : Foil Feeding Machine.
- HPR01: High compressor.
- HPR02: Cooling Tower.
- HPR03: High Air Dryer.
- LPR01: Low Compressor.
- LPR02: Low Air Dryer.
- CHILEER: Chiller.
- R.O01: Ozonated Column.
- R.O02: Storage Tank.
- R.O03: Degassifier.
- R.O04: CIP Tank.
- R.O05: Protec New R.O.#4.
- R.O06: Ozone Generator.
- R.O07: Carbon Filter Tank.
- R.O08: Sand Filter Tank.
- R.O09: Remineralization Unit.
- SUB01: Transformer.
- DEEP01: GRUNFOS Pump.

Equipment Category: T Tools

Object types: HWB will provide before realization phase

3.2.3 Number Range

A piece of equipment must have a unique identification number; this number will be known as equipment
number.
Different Number range is defined for each equipment category.
Internal number assignment will be used for all equipment categories, means that system will
automatically generate equipment number based on the pre-defined number range
HWB equipment numbers will be presented in eight numbers and will use following number ranges:
o M: Production Machines 100000 – 199999
o T: Tools 200000 – 299999
Business Process Blueprint Plant Maintenance Version 1.0 Page 20 of 78
Business Blueprint
PM – Plant Maintenance
3.2.4 Reports

Report Transaction Description


Name
Display IH08 This report is used to output a list of equipments.
Equipment Equipment data comprises general data, serial number
data, location data, and maintenance data. You can use
an equipment list to:
Search for an equipment whose number you do not
know
Compile a list of equipment based on particular criteria
Perform collective processing for equipments with
particular characteristics
Equipment List IE07 This report outputs a multi - level list of equipments. You
(Multilevel) can use a multi - level equipment list to:
Search for an equipment whose number you do not
know
Compile a list of equipment based on particular criteria
Perform collective processing of equipments with
particular characteristics
With multi - level lists there are possible filtering criteria
for the search. You can change the filter criteria as
required and the results will be displayed depending on
the selected filters.
Equipment IH04 You use this report to obtain a structure display in list or
Structural graphic form based on equipment. You can use the
Display explosion (Show Details and Hierarchy of an Equipment)
to set different views:
 Position of the equipment within the equipment
hierarchy (Equipment may have superior
equipment or subordinate equipment)
 Equipment with Equipment BOM (Assemblies
and materials which are the components of the
equipment)

3.2.5 Integration Points

No Description Module
1 Assign Material and Material Serial Number MM
2 Assigning Cost Centres Controlling (CO)
3 Assigning fixed asset number to equipments FI

Business Process Blueprint Plant Maintenance Version 1.0 Page 21 of 78


Business Blueprint
PM – Plant Maintenance

3.3 Fleet Objects


In addition to the normal components of the equipment master record, the following fleet-
relevant data is available in the SAP system:
 Measurement data (for example, height, width)
 Transport-relevant data (for example, weight, maximum load weight, maximum
load volume)
 Engine data (for example, engine type, engine power, number of revolutions per
minute)
 Fuel and lubrication data (for example, fuel type, oil type, calculation method)
Following sections will describe the following in detail:
 What is fleet object?
 What is the difference between fleet objects and equipments?
 How will fleet objects benefit HWB?

3.3.1 High Level System Realization Concept

The SAP system shows a fleet object as an equipment master record with fleet-relevant data. Like
all equipments, you can also use the fleet object as a reference object for maintenance or service
tasks.

1. In HWB the term 'fleet object' includes Cars, Trucks, Van, Refrigerated Truck, and Fork Lift
In addition to the normal components of the equipment master record, the following fleet-relevant
data is available in the SAP system:
 Measurement data (for example, height, width)
 Transport-relevant data (for example, weight, maximum load weight, maximum load
volume)
 Engine data (for example, engine type, engine power, number of revolutions per minute)
 Fuel and lubrication data (for example, fuel type, oil type, calculation method)
Note: Additional function can be used with Fleet Objects (Calculating the consumption of fuel) and it
will be covered later in the section (Measuring Points and Counters)

3.3.2 Configuration Considerations

There is a Key for distinguishing individual Fleet Objects according to their use; this key is
called Equipment Category
IN HWB:
Example:
Fleet Object Category: V
Object types:
- VEH01: Pickup.
- VEH02: Sedan.
- VEH03: Diana.
Business Process Blueprint Plant Maintenance Version 1.0 Page 22 of 78
Business Blueprint
PM – Plant Maintenance
- VEH04: Truck.
- VEH05: Mini-bus.
- VEH06: Bus.
- VEH07: Fork Lift.

3.3.3 Number Range

o V: Fleet Objects 300000 - 399999

3.3.4 Reports

Report Transaction Description


Name
Display Fleet IH08 This report is used to output a list of Fleet Objects (e.g.
Object Locomotive - Passenger cars – Long Distance
Wagons….etc.). Fleet Object data comprises general
data, location data, and maintenance data. You can use
an Fleet Object list to:
Search for a fleet object whose number you do not know
Compile a list of fleet objects based on particular criteria
Perform collective processing for fleet objects with
particular characteristics
Fleet Object IE07 This report outputs a multi - level list of fleet objects. You
List can use a multi - level Fleet Object list to:
(Multilevel) Search for a fleet object whose number you do not know
Compile a list of fleet objects based on particular criteria
Perform collective processing of fleet objects with
particular characteristics
With multi - level lists there are possible filtering criteria
for the search. You can change the filter criteria as
required and the results will be displayed depending on
the selected filters.
Fleet Object IH04 You use this report to obtain a structure display in list or
Structural graphic form based on a fleet object .You can use the
Display explosion (Show Details and Hierarchy of an Fleet
Object) to set different views:
 Position of the fleet object within the functional
location hierarchy
 Position of the Fleet Object within the Fleet
Object hierarchy (Fleet Object may have superior
Fleet Object or subordinate Fleet Object, e.g.
Locomotive may be superior Fleet Object for
generator)
 Fleet Object with Fleet Object BOM (Assemblies
and materials which are the components of the
Fleet Object)
Business Process Blueprint Plant Maintenance Version 1.0 Page 23 of 78
Business Blueprint
PM – Plant Maintenance
3.3.5 Integration Points

No Description Module
1 Assigning Cost Canters to Fleet Objects Controlling (CO)
2 Assigning fixed asset numbers to Fleet Objects Financial (FI)

Business Process Blueprint Plant Maintenance Version 1.0 Page 24 of 78


Business Blueprint
PM – Plant Maintenance

3.4 Installation and Dismantling


Installation and dismantling a piece of Fleet Object is performed when a piece of Fleet Object or
Equipment is damaged (broken-down) or is needed to be replaced, In this way a piece of Fleet
Object can be tracked against where used list where all the history of Fleet Object location is
documented
Also the Fleet Object is linked with a material that has a serial number, so when the damaged
(broken-down) Fleet Object is dismantled, it can automatically be placed in storage. Likewise,
when the spare part is withdrawn from storage it can automatically be installed at the fleet object
or Equipment.
Following sections will describe the following in detail:
 What is installation and dismantling of Fleet Object?
 How will installation and dismantling of Fleet Object benefit HWB?

3.4.1 High Level System Realization Concept

In HWB, Components can be installed and dismantled at main Equipments. You can monitor the
installation times for any Component from both the Equipment view and the component view.
The Fleet Object, and Equipment are linked with a material that has a serial number, so when the
damaged Fleet Object, or Equipment is dismantled, it can automatically be placed in storage.
Likewise, when the spare part is withdrawn from storage it can automatically be installed at the fleet
object.
The installation locations for any Equipment within a fleet object, or Equipment are documented in
the usage list.
As well as changes to the installation location, the usage list also documents changes to other fields
of the master record (for example, cost center, asset, and so on).
Usage list provides information about Fleet Object. Fleet Object description, valid from date, valid to
date, planning plant, functional location and superior Fleet Object

The table below displays the output from the usage list:

Object Description
Equipment Equipment Code
Description Equipment Description
Valid From Installation Date
Valid To Dismantle Date
Functional Location Old Functional Location
New Functional Location
Superior Fleet Object Old Superior Equipment
New Superior Equipment

Business Process Blueprint Plant Maintenance Version 1.0 Page 25 of 78


Business Blueprint
PM – Plant Maintenance
3.4.2 Process Flow:
Business Process Flow

Input Process Steps

Fatal Malfunction
Start
Happened

Create an
Equipment Need
No order for Complete the work order as normal cycle
to change
reapairing

Yes

Create new work order to dismantle


and install Equipments End

Order Settlement
Plan the wok order

Complete the work order and the


notification
Release the work order

Dismantle the damaged


equipment and send it
to warehouse
Confirm the work order and enter the
Execute the activates in the work technical findings
order
Install New / Repaired
equipment and issue it
from warehouse

3.4.3 Assumptions

 Organization structure is well defined


 Serial Numbers for required Fleet Objects and HWB Equipments are available
 Storage locations are well defined
 Fleet Object, IT Devices will be dismantled and sent for storage location in the system only if it
will be maintained by Subcontractor
 Account Assignment information must be available for each Fleet Object
Business Process Blueprint Plant Maintenance Version 1.0 Page 26 of 78
Business Blueprint
PM – Plant Maintenance
3.4.4 Reports

Report Name Transaction Description


Display Serial IQ09 You can use this report to generate a list of serial
Number for Material numbers. You can use this list to:

 Search for a serial number whose number you do not


know
 Perform collective processing for particular serial
numbers

3.4.5 Integration Points

No Description Module
1 Assigning Cost Centers to technical objects (Main Controlling (CO)
Equipments- Sub-Equipment)
2 Assigning fixed asset numbers to Fleet Objects Financial (FI)
3 Assigning material number and serial number to Fleet Material
Objects Management (MM)

Business Process Blueprint Plant Maintenance Version 1.0 Page 27 of 78


Business Blueprint
PM – Plant Maintenance

3.5 Bill of Material


A maintenance bill of material (BOM) is a complete, formally structured list of the components
making up a technical object. The list contains the object numbers of the individual components
together with their quantity and unit of measure.
Maintenance BOM will ease the processing of a maintenance order by selecting the required
components directly from the reference object BOM
The following sections will describe the following in detail:
 What is Bill of Materials and what are its types?
 How will Bill of Material benefit HWB?
 Single level and multi level bill of material?
 Process flow of creation and changing Bill of Materials?

3.5.1 High Level System Realization Concept

Maintenance BOMs are primarily used for the following purposes:


 Structure description
Maintenance BOM describes the structure of a technical object or material. Using
maintenance BOMs you can specify exactly where maintenance tasks are to be performed
on a technical object.
 Assignment of spare parts
A maintenance BOM is used in plant maintenance to assign spares for a technical object or
material.
Using maintenance bills of material presents the following advantages:
 Materials planning (when using maintenance task lists)
The use of maintenance BOMs is advantageous for material planning, because you can
perform material planning when creating a maintenance task list.
The link between task list and maintenance BOM enables you to assign materials that have
already been planned for the technical object to the individual operations in the task list. You can
use the structure list or the structure graphic to do this. As both display options provide a detailed
overview of all the materials of the BOM, material planning is simplified considerably.
 Materials/spares planning (when using maintenance orders)
Maintenance bills of material support you during materials or spares planning by providing
you with an overview of all materials/spare parts that could be required in the maintenance
order. This enables you to assign to the order all the materials you require and makes
materials/spares planning considerably easier.

 Locating malfunctions (when using maintenance notifications)

Maintenance bills of material support you when locating malfunctions by providing you with
an overview of all components that make up a technical object. From this overview you can
easily select the object for which you want to create a malfunction report. This enables you to
locate the malfunction in the technical object more precisely.
Note:
Business Process Blueprint Plant Maintenance Version 1.0 Page 28 of 78
Business Blueprint
PM – Plant Maintenance
In Plant Maintenance, multi-level bills of material (BOMs) are usually used. They can have as
many levels as required. The highest level in a multi-level BOM (Level 0 in the figure below)
represents. The lower levels of the BOM (Levels 1 and 2 in the figure below) represent the
components making up the technical object, and their components
Before bills of material can be defined for any module, the materials that make up the bill of
materials must first be defined, typically from the MM (Materials Management) module. Work
with those responsible for the maintenance of material records to define materials required
for BOM use.

Level 0 Car

weels Engine Motor Body


Level 1

Level 2 Valves Piston Distibutor

3.5.2 Configuration Considerations

Material Type used in maintenance BOM is ‘ERSA Spare Parts’, (for more information regarding
material types refer to HWB MM blueprint)

Operating supplies material type, will use a material group for maintenance

Item Category allows you to process data that is relevant to the individual items in a BOM. The item
category is used to control field selection, default values for BOM maintenance, triggering of specific
system activities like purchase requisition in case of the non-stock material, following item categories are
used in Maintenance Bill of Materials
o Stock Item L
o Non-stock Item N
Refer to MM blue print (procurement of consumable materials (126))

3.5.3 Number Range

Number range for material BOM will be the same for material Type Spare parts.
Internal assignment of number ranges

3.5.4 Integration Points

No Description Module
1 Assigning Material Numbers to BOM Material Management (MM)

Business Process Blueprint Plant Maintenance Version 1.0 Page 29 of 78


Business Blueprint
PM – Plant Maintenance

3.6 Permits
Permits are used to ensure that special approval must be obtained before orders are executed.

Permits are used to adhere to health and safety regulations, and control order processing.

In HWB Permits will be used in two ways:

 As process-oriented permits with automatic assignment to the order

Process-oriented permits are determined automatically based on a field in the order


header and can likewise influence the order release like (Planned Cost).

You can select orders and technical objects according to assigned permits.

The following sections will describe the following in detail:


o What is a Permit?
o What are permit types?
o How will Permits benefit KMT?

3.6.1 High Level System Realization Concept

The permit can control the release of an order or the completion of an order. If it is controlling the
release of the order, the system will not allow releasing the order without issuing the permit and
same will be the cases where the permit has a control on completion.

The permits assigned to the orders are to be issued by an authorized person after checking
physical condition. One can get the list of permits pending for issue for a particular period. We
can assign multiple permits at a time to an order and these permits are to be issued by the
authorized person.

Because the term ‘permit’ covers all possible types of regulations or conditions, individual
permits are combined in logical permit categories to achieve a better overview of them

3.6.2 Organizational Implications / Considerations

 Master Data Maintenance

It is required to have Central Master Data Maintenance team in order to manage and maintain
the SAP PM Master Data elements. Master Data Maintenance role will be also needed at the
plant level with master data change authorization.

 Standardization of Master data for all plants in HWB

Business Process Blueprint Plant Maintenance Version 1.0 Page 30 of 78


Business Blueprint
PM – Plant Maintenance
It is required to have an approval process step to ensure data integrity. This will be crucial to
ensure the validity of PM Master Data for HWB.

3.6.3 Configuration Considerations

N/A

3.6.4 Number Range

3.6.5 Reports
N/A

3.6.6 Integration Points


N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 31 of 78


Business Blueprint
PM – Plant Maintenance

3.7 Work Centers


A work center represents a group of one or more people. Work centers are assigned to plants in
SAP. Each work center will have an association with a cost center and one or more activity types
up to six activity types (e.g. regular time, overtime, emergency response) to calculate planned
and/or actual costs for the work order. Work centers representing skilled labor will be maintained
through SAP HR by assigning the employee’s position to the Work Center. The use of work
centers to define specific groups of skilled labor will enable better scheduling and tracking of all
maintenance operations within HWB

An hourly rate is maintained as a Controlling (CO) Activity type with a cost element used for
planning. The CO Activity type cost element is a loaded average of labor and/or Fleet Object
rates. Actual hourly rate charges are posted to the work order via time confirmation transactions
(IW41).

Work center data forms the basis for: cost, capacity, and target date calculation

Work Center is used to help:

 Define which personnel should be used for the operations


 Calculate costs, capacities and target dates for the operations
Following sections will describe the following in detail:
 What are Work Centers?
 What are Work Centers Categories?
 Coding of work Centers in HWB
 Process flow of creation and changing work centers

3.7.1 High Level System Realization Concept

Work center contains the following data:

 In HWB, work center will be only one maintenance workcenter for the whole factory
 The following data should be entered at work center creation:
o Costing: You can use costing to determine the costs of an internal activity
(Maintenance activity). Its goal is to assign to the various cost objects the costs
that were incurred by them. If the work center is used in an operation, the link to
the cost center provides activity types for evaluating the operation. Every work
center will be assigned to plant and cost center and one or more activity type.

o Scheduling: You can use scheduling to determine the dates when operations
should be performed. For this, the time required for the operations must be
Business Process Blueprint Plant Maintenance Version 1.0 Page 32 of 78
Business Blueprint
PM – Plant Maintenance
calculated and compared with the time available in the work center. The standard
values and quantities in the operations are used as the basis for this calculation.
During scheduling, the start and end dates for the operations are calculated from
this data using formulas, which have been entered for scheduling in the work
centers.

o Capacity planning: In capacity planning, the capacity requirements for the


operations in the orders are determined and compared with the available capacity
defined in the work center. Capacity of each work center - resource availability -
will be added in terms of total available working hours during the working days for
the capacity category (labor).

o Personnel data: In addition to defining available capacity, people (= personnel


numbers from Human Resources) or positions can be assigned in the work
center.

o Standard values: are planned values for the execution of an operation and are
maintained in the operation. Typical standard values are, for instance, set-up time
and maintenance processing time.

 A control key uses the following keys and indicators to determine how an operation or a
sub operation is to be processed in a task list. Examples of such keys and indictors are:
o PM01: Plant maintenance – internal
o PM03: Plant maintenance - external (services)

 Every Control Key may contain one or more of the following parameters:

o Scheduling: If you set this indicator, the system carries out scheduling for an
operation or it determines the earliest or latest dates for a sub-operation. If you do not
set this indicator, the system does not schedule the operation or sub-operation, the
system automatically sets the duration to zero.

o Capacity planning: If you set this indicator, the system creates capacity requirement
records for the operation or sub-operation. If you set this indicator for a control key,
you must also set the scheduling indicator.

o Confirmation: Use this indicator to specify whether and how the operation or sub-
operation should be confirmed.

o Costing indicator: Use this indicator to specify whether the operation or the sub-
operation should be costed.

o Time tickets: Use this indicator to specify that time tickets is printed for the operation
or sub operation.

o Print operation: Use this indicator to specify that shop papers are printed for the
operation or sub-operation.

Business Process Blueprint Plant Maintenance Version 1.0 Page 33 of 78


Business Blueprint
PM – Plant Maintenance
o External processing: Use this indicator to specify that the operation or sub-operation
is to be performed by a third party.

 Main work center for maintenance tasks is a Key which uniquely identifies the responsible
work center for this technical object.
 Work Center category will always be (0005) Plant Maintenance.
The work center code is constrained by 8 digits and accepts alphanumeric data

3.7.2 Configuration Considerations

 A control key uses the following keys and indicators to determine how an operation or a
sub operation is to be processed in a task list. Examples of such keys and indictors are:
o PM01: Plant maintenance – internal
o PM03: Plant maintenance - external (services)

3.7.3 Number Range

The work center code is constrained by 8 digits and accepts alphanumeric data

3.7.4 Reports

Report Name Transaction Description


Work Center List CR05 This report outputs a list of work centers. You can use
work center list to:

 Search for a work center whose number you


do not know

 Compile a list of work centers that are in the


same plant or have the same work center
category

3.7.5 Integration Points

No Description Module
1 Assigning Cost Centers and Activity types to Work Centers Controlling (CO)
2 Employees and qualifications, in work centers HRMS

Business Process Blueprint Plant Maintenance Version 1.0 Page 34 of 78


Business Blueprint
PM – Plant Maintenance

3.8 Characteristics

 Characteristic is a property for describing and distinguishing between objects, such as length,
color, or weight
 In HWB we will use characteristics to describe parameters which can't be directly added to
the technical object (Equipment, or Fleet Object):
o For Equipments characteristics will be -for example- Equipment Production Capacity.
o For Vehicles characteristics will be -for example- Gear Type, insurance expiry date.

The following sections will describe the following in detail:


 What are characteristics?
 How will characteristics benefit HWB?

3.8.1 High Level System Realization Concept

 Name of the characteristic must be stated as well as valid from date for each characteristic in
the initial view.
 Basic Data view contains the following:
o Description for every characteristic will be provided.
o The characteristics group can be used to group together similar characteristics. It is used
to make finding characteristics easier
o The characteristic status: gives information on the processing status of the characteristic
(released, in preparation, or locked) and determines whether it can be used elsewhere in
the system.
o Authorization Group: for Characteristics will define whether a user is allowed to maintain
this characteristic or not.
o The data type: shows the format for entering characteristic values (Character format,
Numeric format, Date format, Time format, and Currency format).
o If you want to enter alphanumeric values, select data type CHARS
o Alphanumeric values can be up to 30 characters long.
o You can define whether upper-case and lower-case characters are interpreted as
different. If they are not, all values are automatically converted to upper case.
o Total number of characters that you can enter when you assign a value to this
characteristic can be maintained.
o Characteristics can have single or multiple values.
o You can define that a value must always be assigned to a characteristic during
classification, by setting the Entry required indicator.

Business Process Blueprint Plant Maintenance Version 1.0 Page 35 of 78


Business Blueprint
PM – Plant Maintenance
o If you want to enter intervals as values for a characteristic, set the Interval values allowed
indicator.
o If the data type is set to be numeric, every Characteristic should have a unit of measure;
also we should put the decimal places.
o For numeric values, there is an option to accept negative values.
o To convert values to powers of ten, you can enter exponents. The standard exponent
format converts values to format 1,…E-XX, for example: (1000 = 1.000E+03 and 0,001 =
1.000E-03)
o You can also enter exponents manually, or use scientific exponent format, for example,
mille, micro, or mega.
 Descriptions view: provides Language-dependent description of characteristic.
 Values view: shows the values of the characteristics and determines the default values.
 The Additional data tab includes options for defining various display options.

3.8.2 Configuration Considerations

N/A

3.8.3 Number Range


External numbering system is used for equipment characteristics.

3.8.4 Reports

Report Name Transaction Description


Characteristics List CT10 o You can produce a list for a specific range of
characteristics.
o You can restrict the list by entering a
characteristics group, a data type, a status, the
user who created the characteristic, or the user
who last changed the characteristic.
o You can define whether you see the characteristic
description, the allowed values, the administrative
data, and whether a characteristic is used in
classes or other objects. You can also enter the
language in which you want the descriptions
displayed.

Business Process Blueprint Plant Maintenance Version 1.0 Page 36 of 78


Business Blueprint
PM – Plant Maintenance
Where-Used List for CT11 This where-used list shows you:
Characteristics and
Characteristic o Where a specific characteristic is used
Values
o Which objects have a specific characteristic value
assigned to them

For example, you may want to delete a value, but you


are not allowed, because the value has already been
assigned to objects.

3.8.5 Integration Points


N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 37 of 78


Business Blueprint
PM – Plant Maintenance

3.9 Classes

 Classification means that you assign objects to classes and use the characteristics of the
classes to describe the objects.
 The aim of classification is to assign features in detail to a technical object that cannot be
assigned to the master record by using the fields of the SAP standard system.
 In HWB will group the maintained characteristic (for data which are not included in technical
object data) in a class and assign this class the Equipment.
The following sections will describe the following in detail:
 What are classes?
 What is the use of classes in HWB?
 Process flow of Creation and changing of classes

3.9.1 High Level System Realization Concept

 In the initial screen of classes we fill the class name and class type and valid from date
 You can use the class type to find objects. The search includes all the classes of a
Class type or you can specify the characteristics that are relevant to your search and
enter values
 The class type is used to define a number of parameters, such as:
o The objects that can be classified in a class
o Whether objects of different object types can be classified in the same class
o Whether an object can be classified in more than one class of the same class type
o The class maintenance screens that can be processed
 Each class must be assigned to exactly one class type; in HWB we will use Fleet Object
Class Type and Equipment Class type.
 In the Basic Data view , we determine:
o Description for every class should be provided.
o Valid from and valid to dates for each class should be maintained.
o Authorization groups to restrict authorizations for class maintenance, classification, and
finding objects for specific classes.
o The class group: can be used to group together similar classes. The class group is used
for finding classes quickly
o The class status: gives information on the processing status of the class (released, in
preparation, or locked) and determines whether it can be used elsewhere in the system.
 In Characteristic tab: Characteristics are assigned to class and we can assign more than one
characteristic to one class. There are two assignment functions:
Business Process Blueprint Plant Maintenance Version 1.0 Page 38 of 78
Business Blueprint
PM – Plant Maintenance
o You can assign an object to one or more classes. On the initial screen of this function,
you enter the object. The same assignment function is available when you classify an
object in its master record.
o You can assign several objects to a class at the same time. On the initial screen of this
function, you enter the class.

3.9.2 Configuration Considerations

The classification system is a central SAP component. The class type determines how classes are
processed, and how objects can be classified and retrieved in these classes
Class type used for equipment:

002 Equipment class

3.9.3 Number Range

External numbering system is used for equipment classes.

3.9.4 Reports

Report Name Transaction Description


Class List CL6AN The class list function lets you list classes according to
various criteria. You can list:

o All classes whose names you enter, or all classes


in a specific name range
o All classes in a class group, all classes created or
changed by a specific user, or classes with a
specific status
o Only classes with assignments

3.9.5 Integration Points

N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 39 of 78


Business Blueprint
PM – Plant Maintenance

3.10 Measuring Points and Counters

 Measuring points: are physical and/or logical locations at which a particular condition is
described. They are located at technical objects (Fleet Object or Equipment)
 You can use the measuring point category to distinguish between measuring point attributes
that differ from group to group.
 Counters: are resources that enable you to represent the wear and tear of an object or the
consumption or reduction in its useful life, for example, the kilometer indicator of a car;
counters are located at technical objects
 Counters are special type of measuring points and are represented in the system as a form
of measuring point.
 Each measuring point or counter refers to a characteristic with specific measuring unit (for
example, kilometer, liter, operating hours).
 Counters can run forwards, the counter readings increase, or backwards, counter readings
decrease, but in HWB we will always use forward counters.
The following sections will describe the following in detail:
 What are measuring points and counters?
 What is the difference between measuring points and counters?
 The use of measuring points and counters in HWB

3.10.1 High Level System Realization Concept

 In HWB we will use fleet objects counters, for this we have to define the counters which are
used to calculate the consumption data of the vehicles, we will use:
o Fuel counter that measures Fuel Consumption,
o Primary counter (performance counter) to measure distance in Kilometers.
 On the basis of the counter readings, you can calculate the average daily consumption of the
fleet object, such as the average consumption of the fuel consumed daily.
 The characteristic of a measuring point or counter determines the characteristic unit in which
measurement and counter readings are entered.
 Number range for counters will be internal and starts from 0000001 to 9999999
 You can enter measurement or counter readings for each object to be maintained. This
makes sense if you want to document the condition of an object based on measurement
readings or if the regular maintenance of an object depends on its meter readings.
 Measurement Document: is the overall term used to describe the data entered in the system
after measurement at a measuring point or after a meter reading.
 A measurement document consists of the following data sections:

Business Process Blueprint Plant Maintenance Version 1.0 Page 40 of 78


Business Blueprint
PM – Plant Maintenance
o Measuring point data: This refers, for example, to the measuring point number,
measurement position, description, characteristic, and unit
o Measuring point category: to distinguish between measuring point attributes that differ
from group to group.
o Counter reading and the difference between this reading and the previous reading.
o Measurement result data: This refers to the precise second when the measurement
reading (time stamp) takes place, the measurement or counter reading respectively, as
well as a qualitative assessment of the measurement result if necessary
o If necessary, additional information (as short and long text): This refers to the
information describing which technician performed the measurement or reading and, if
necessary, the number of the measurement document from which the measurement
result or counter reading was derived
o In addition, you can assign a processing status to the measurement document. This
status can indicate a need for action based on the measurement value or counter
reading and whether the need for action based on these readings is already covered by
an existing task.

3.10.2 Configuration Considerations

HWB Measuring Points Category will be M = General Measuring Point

3.10.3 Number Range

Number range for counters will be internal and starts from 0000001 to 9999999

3.10.4 Reports

Report Name Transaction Description


Display IK07 This report outputs a list measuring points/counters. You
Measuring can use a measuring point list to:
Points
 Search for a counter whose number you do not
know

 Compile a list of counters that have the same


characteristics

 Perform collective processing of counters that


have the same characteristics

N.B: in HWB we will mainly use Counters not Measuring


Points.
Display IK17 This report outputs a list of measurement documents for
Measurement measuring points/counters. You can use a measurement

Business Process Blueprint Plant Maintenance Version 1.0 Page 41 of 78


Business Blueprint
PM – Plant Maintenance
Documents document list to:

 Search for a measurement document whose


number you do not know

 Compile a list of measurement documents that


have the same characteristics

 Perform collective processing for measurement


documents that have the same characteristics

Display S_ALR_870 You can use this report to display and, where necessary,
Measurement 13421 print out an existing measurement reading entry list. You
Reading Entry use a measurement reading entry list to put together
List measuring points and counters in a freely definable
sequence so that measurement readings can then be
entered for them. You can print out this list for the person
who will be taking the readings, so that he can write his
results on the paper version of the list.

3.10.5 Integration Points

N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 42 of 78


Business Blueprint
PM – Plant Maintenance

3.11 Catalogues

 Catalogues are used when maintaining notifications for the coded entry of results and
activities. Coded entry is particularly useful for analysis. There are certain standard analyses
in the Plant Maintenance Information System (PMIS), which can be used to analyze these
codes.
 The following terminology will be found while creating a catalog profile:
o Catalog: Combination of code groups, grouped together according to content (For
example, damage, cause of damage, object parts, Tasks, and activities)
o Code groups: Combination of codes, grouped together according to content (For
example, damage of Dialysis machine, Blood Warmers, and Chiller unit). and so on
o Codes: Description of damage
The following sections will describe the following in detail:
 What are Catalogues?
 The structure of Catalogues
 The different types of Catalogues
 Advantages of Catalogues

3.11.1 High Level System Realization Concept

 The following figure shows an example for Vehicle Catalog Profile:


Vehicle
Catalog
Profile

Vehicle
Vehicle Vehicle Vehicle
Cause of Vehicle Parts
Tasks Activities Damages
Damages (Catalog)
(Catalog) (Catalog) (Catalog)
(Catalog)

Vehicle Vehicle
Electrical Mechanical
Damages Damages
(Code Group) (Code Group)

misalignment Oil leakage


(Code) (Code)

 Advantages of Catalogues :

Business Process Blueprint Plant Maintenance Version 1.0 Page 43 of 78


Business Blueprint
PM – Plant Maintenance
o No incorrect entries
o Evaluations and reporting are possible using the standard analyses in the Plant
Maintenance Information System
o Codes can be used as the starting point for workflows and follow-up actions
 In the catalog profile, you can define which code groups can be used when processing a
specific object. The advantage here is that only the code groups relevant for the object are
displayed.
 Catalogues are assigned to each notification type for the following predefined areas:
Problems, causes, tasks, activities and object parts.

3.11.2 Configuration Considerations

N/A

3.11.3 Number Range

N/A

3.11.4 Reports

N/A

3.11.5 Integration Points

N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 44 of 78


Business Blueprint
PM – Plant Maintenance

3.12 Task List


Maintenance task lists describe a sequence of individual maintenance activities which must be
performed repeatedly within a company. Task lists are used to standardize these recurring work
sequences and to plan them more effectively. Maintenance task lists contain important
information such as the spares and tools required for the work steps or the time required
performing the work.
The following sections will describe the following in detail:
 What is task list and what are its types?
 The Importance of task lists in Maintenance
 Use of task lists in HWB

3.12.1 High Level System Realization Concept

In HWB we will use one type of maintenance task lists:


1. General Task list

General maintenance task lists are task lists that are used for general maintenance tasks.
They do not refer to a specific technical object. Using general maintenance task lists, you
can define and manage sequences of maintenance tasks centrally, and use them for
work scheduling.

Within a group, you can create several individual general maintenance task lists. The
system automatically assigns a sequential number, the group counter, to each general
maintenance task list. This clearly identifies each general maintenance task list within the
group.

Use
You can use these task list types for both
 Planned maintenance
 Unplanned maintenance

Structure
Maintenance task lists (PM task lists) are grouped into task list groups. A task list group
includes all maintenance task lists with similar maintenance flows.
The task list group has more significance for general task lists, as they are called up
using the task list group number. Group numbers for general task lists can be assigned
either internally or externally. Group numbers for Fleet Object task lists and task lists for
functional locations can only be assigned internally.

The master record for the task list uses the following views:
 Header Data

Business Process Blueprint Plant Maintenance Version 1.0 Page 45 of 78


Business Blueprint
PM – Plant Maintenance
The maintenance task list header contains data that is valid for the entire maintenance
task list for example (short description, task list planner group, and status, usage and
maintenance strategy

 Operation

You can describe the individual maintenance tasks to be performed in the operations. An
operation specifies the time, work center and other control information required for the
maintenance task. You can describe how the task is to be performed in the operation
text.
In the maintenance Process, there are basically two options for assigning work to be
performed:

1- Internal Processing:
In this case maintenance tasks to be performed by the internal workshops, which
are defined in the system as maintenance work centers
The following data are required when using internal operations:
o Main Work Center: The main work center usually represents one person or a
department, responsible for ensuring that the maintenance work in an order is
executed by the work centers performing the individual operations.
o Control Key: It is a default value which defines whether the operation should be
done by internal resources or using external services by external company
o The description of the task
o Work: the total amount of man hours used for accomplishing the process
o Number of persons : the number of workers involved in this activity

2- External processing
In this case, the operation will be executed by a third party based on individual
purchase order

 Sub operations
You can create sub-operations for all the operations in a maintenance task list.
Sub operation represents an additional level of detail for an operation and is
situated hierarchically below an operation. You can assign several sub-
operations to one operation this can be an advantage if several work centers are
required in one operation.

 You can assign the following objects to the operations:


o Material components
o Production resources/tools
o Maintenance packages

Business Process Blueprint Plant Maintenance Version 1.0 Page 46 of 78


Business Blueprint
PM – Plant Maintenance
3.12.2 Configuration Considerations

Standard configuration

3.12.3 Number Range

General task list 1-10000

3.12.4 Reports

Report Name Transaction Description

Display Task Lists IA09 You can generate a list of maintenance task lists using
this report.

You can choose from several restrictive criteria to


select the task lists. You will then receive a list of all the
task lists that fulfill the selection criteria you have
specified.
Display Task Lists IA10 You can generate a structured list of maintenance task
(Multilevel) lists or service task lists using this report.

You will then receive a structured list of all the task lists
that fulfill the selection criteria you have specified.

You can also generate lists independently of operations


(for example, all PRTs and materials used) and display
operations and sub - operations separately
Cost Maintenance IA16 You can perform a costing for maintenance task lists or
Task Lists operations in a task list using this report. The system
calculates the costs for which the selected task lists or
operations are responsible.
Print Maintenance IA17 You can print maintenance task lists and service task
Task Lists lists using this report.

3.12.5 Integration Points

No Description Module
01 Assign Material Components to a Task List MM
02 Assign External Service Operations to a Task List MM
03 Assign Work Centers and Activity Types to a Task List FICO

Business Process Blueprint Plant Maintenance Version 1.0 Page 47 of 78


Business Blueprint
PM – Plant Maintenance

3.13 Maintenance Strategy


A maintenance strategy defines the rules for the sequence of planned maintenance work. It
contains general scheduling information, maintenance packages and can therefore be assigned to
as many maintenance task lists and maintenance plans as required.

The following sections will describe the following in detail:


 What is maintenance strategy
 Structure of maintenance strategy
 Maintenance Packages

3.13.1 High Level System Realization Concept

Structure
A maintenance strategy consists of:

 Strategy Header

o Name of the strategy


o Short text

 Scheduling Parameters

The scheduling parameters (for example, call horizon, shift factor) contain the scheduling
data for the respective maintenance strategy, with which you can influence the
scheduling of maintenance plans. When you create a strategy plan, the system copies
this data to the plan where you can change it.

 Scheduling Indicators

Within a maintenance strategy, you can use different scheduling indicators to specify the
type of Scheduling you require:
o Time-based (for example, every 30 days)
o Time-based by key date (for example, every 30 days on the 30th day of the
month)
o Time-based by factory calendar(for example, every 30 working days)
o Performance-based (for example, every 10000 Kilometer)

 Maintenance Packages
Maintenance activities that must be performed at a particular date or point in time are
combined into maintenance packages. These contain, for example, the cycle duration
and unit of measurement.

Use
In HWB the two types of maintenance strategies can be used. One will be for time based
maintenance and another will be for (Performance) counter based maintenance. The
counter based strategy consists of Distance traveled (Kilometer), etc.
Business Process Blueprint Plant Maintenance Version 1.0 Page 48 of 78
Business Blueprint
PM – Plant Maintenance
3.13.2 Configuration Considerations

N/A

3.13.3 Number Range

Maintenance strategy consists of six characters alphanumeric.

3.13.4 Reports

Report Name Transaction Description


Where - Used List IP14 o You can use this report to perform a where - used
by Strategy list for a maintenance strategy.
o The system creates a list with all maintenance
plans in which the strategy is used.
o The basic list contains the number of the
maintenance plan, its short text, the strategy and
the number of maintenance items.
o You can call up the detail screen of a maintenance
plan from the list

3.13.5 Integration Points

N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 49 of 78


Business Blueprint
PM – Plant Maintenance

4 Corrective Maintenance (929)


4.1 Business Process Diagrams
Corrective Maintenance
Role Process
Master

Team
Data

Functional Work
Equipment BOM Catalogs Matetrial
location Centers
Requester/
Initiator

10.0
Start Maintenance
Notification

20.0
Create 30 100 110.0
Maintenance Emergency NO Time Enter Technical
Order YES
Confirmation Findings
Maintenance Planner

80
NO External Service 90.0 120.0
exist YES Service Entry Complete order
30.1 Sheet Technically
40.0
Plan
Release order
Maintenance
Order

Operations
, Materials, Yes
Services
Executer

50.0 60.0 70.0


Print Order All Activities are
Maintenance Execution Completed?
order
No
Departments

40.1
Other

60.1 140.0 130.0


MM Purchase Requisition for non
MM Goods CO CO Order
stock items and external services
Issue Order Close Settlement

Business Process Blueprint Plant Maintenance Version 1.0 Page 50 of 78


Business Blueprint
PM – Plant Maintenance

4.2 Business Process Description


Operational Maintenance is the process of maintaining the Technical Objects whenever a breakdown or
failure occurs. It is therefore possible to process a repair using many planning stages, such as
preliminary costing, work scheduling, material provision, resource planning and permits. However, it is
also possible to react immediately to damage events causing production shutdown, and to produce the
required orders and shop papers with the minimum of entries in the shortest possible time. Therefore
operational Maintenance process is divided into two processes:
 Corrective Maintenance.
 Breakdown Maintenance

In operational maintenance there are two main SAP document used to manage the process:
 Maintenance Notification: to report and document all malfunction history
 Maintenance Order: to plan and control all maintenance activities and required resources to
execute these activities.

Process Characteristics
Process Trigger Maintenance Notification
Process Input Malfunction data
Process Output Maintenance Order
Process Owner Maintenance Department
Process Volumes
Process Frequencies Daily

4.3 Process Step Detailed Requirements & Solution


Process Step Description
GAP
Ref. to Measure
Descriptio
Process Step Requiremen of
ID Solution Description n
Description ts as successfu
(WRICEF
applicable l delivery
ID)
929- Entering Saved A Maintenance request
001 Maintenance describes a malfunction on a
Request maintenance object that in
some ways impairs the
performance of the object.
The malfunction report
documents that:
A technical system is not
functioning correctly.
A technical system is not
working as well as it should or
is not working at all.

Business Process Blueprint Plant Maintenance Version 1.0 Page 51 of 78


Business Blueprint
PM – Plant Maintenance

929- Entering a Saved Order processing helps you to


002 Maintenance Order plan maintenance tasks in
greater detail, for example,
those from a malfunction
report. You decide whether
the tasks to be carried out
should be processed internally
or externally and what
components (materials) you
need for them.
Furthermore, the maintenance
order is used to collect all
costs for a maintenance task
and to debit the cost center
that incurred the costs using
the settlement functions in the
CO module (Controlling).
929- Release Released Release order to be able to
003 Maintenance Order issue goods and start
executing all maintenance
activities
Goods Issue to After the order is released, the
Maintenance Order Maintenance Employee prints
the pick-list and picks the
spare parts according to the
929- order. The system performs a
004 goods issue
Create Purchase The purpose of this activity is
Order from to create the Purchase Order
Purchase for the purchase requisitions
Requisition in that are created for external
Maintenance Order services and external
929- operation in the maintenance
005 order.
Create Purchase The purpose of this activity is
Order from to create the Purchase Order
Purchase for the purchase requisitions
Requisition in that are created for non-stock
929- Maintenance Order material in the maintenance
006 for Non-Stock order.
Approval of Purchase orders that require
929- Purchase Orders an authorization can be
007 approved in this step.
Goods Receipt to Confirm the goods receipt of
929- Purchase Order external operation and non-
008 stock material.

Business Process Blueprint Plant Maintenance Version 1.0 Page 52 of 78


Business Blueprint
PM – Plant Maintenance
Maintain a Service In this activity, the performed
929- Entry Sheet services are reported in the
009 service entry sheet.
929- Approve the In this activity, the service
010 Service Entry entry sheet is approved by the
Sheet company. When this is done
the vendor can send an
invoice for the approved
amount to the service
provider.
929- Invoice Receipt to Send bill for the vendor
011 Purchase Order
929- Show Costs on Display cost overview in
012 Maintenance Order maintenance order
929- Confirming a In this step, time confirmation
013 Maintenance Order would be carried out for the
refurbishment order.
929- Complete the tasks Notification In this step you complete the
014 in the Notification Completed notification by entering all
technical finding to be kept in
history for the equipment
929- Technically Order If an order has been executed,
015 Completing a Technically it must be completed in the
Maintenance Order completed system. This shows that the
order has been processed. In
the PM module, there are two
types of completion, technical
completion and business
completion.
Technical completion shows
that an order was technically
successful or it can be viewed
as technically completed by
Plant Maintenance.
The following shows how
technical completion works
929- Settling the In this activity, you settle the
016 Maintenance Order actual costs of the
maintenance order to the cost
center, internal order or asset
under construction

Business Process Blueprint Plant Maintenance Version 1.0 Page 53 of 78


Business Blueprint
PM – Plant Maintenance

929- Closing the In this activity, you complete


017 Maintenance Order the maintenance order.
- Business View Business completion takes
place when purchasing or
invoice verification has posted
outstanding invoices for
external services or external
materials for the order and the
order is then settled via the
settlement functions in the CO
(Controlling) module.

4.4 Key Policies/Operational Decisions or Logic within the Process


NA

4.5 Integration Points


Integration Points
Integration SAP
ID Data Element Contacts
Point Component
1 Purchase MM
Requisition
2 Goods MM
Movement
3 Order CO
Settlement

4.6 Potential Future Process Improvements (out of scope for this


implementation)
NA

4.7 Organization Structure Considerations


Organizational units related to the process:
 Maintenance/Planning Plants
o 1000 NOVA Water Production Plant
o 1002 Vehicle Workshop
 Planner groups
NOVA Water Production Plant Planner Groups are:
o 100 Mechanical Group
o 200 Electrical Group
o 300 Blow Molding & Injection
o 400 General Repair Group
o 500 ACs

Vehicle Workshop Planner Groups are:


o 600 Vehicles
Business Process Blueprint Plant Maintenance Version 1.0 Page 54 of 78
Business Blueprint
PM – Plant Maintenance

4.8 Master Data Considerations (including all relevant data relationships)


Master data element that will be used with the process:
 Functional Location
 Equipment
 Work Center
 Maintenance Bill of Material(BOM)
 Material

4.9 System Configuration Considerations


Maintenance Notification types that will be used in operational Maintenance are:
 M1 Mechanical Maintenance
 M2 Electrical Maintenance
 M3 Blow Molding Maintenance
 M4 General Maintenance
 M5 ACs Maintenance
 V1 Vehicle Maintenance

Maintenance Order type will be used in operational Maintenance are:


 PM01: Factory Corrective Maintenance
 VM01: Vehicle Corrective Maintenance

PM Activity type per operational maintenance order types:


 PM01: Corrective Maintenance
o 100 Mechanical Maintenance
o 200 Electrical Maintenance
o 300 Blow Molding & Injection Maintenance
o 400 General Repair Maintenance
o 500 ACs Maintenance.

User status for Maintenance orders (PM01):


 Created
 Pending:
Reasons for pending will be as below:
o Waiting for spare parts
o Waiting for external technician
o Waiting for fabricating
 In process
 Cancelled
 Completed

Business Process Blueprint Plant Maintenance Version 1.0 Page 55 of 78


Business Blueprint
PM – Plant Maintenance

4.10 Reporting (operational and analytical)


Reporting
Report Type
WRICEF
Description (ABAP, BI, Data Elements Relevant KPI Owner
ID
BOBJ)
929- Notification List
Standard
R001
929- Order List Standard
R002
929- Cost Analysis Standard
R003
929- Breakdown Standard
R004 Analysis
929- Material Standard
R005 availability

4.11 Interfaces
N/A

4.12 Enhancements
N/A

4.13 Output (e.g. forms)


Output/ Forms
Output
WRICEF Data Object Type
Description Frequency Volumes Owner
ID (Sales Order) (Form,
EDI, etc.)
929- Factory Maintenance Form Per order
O001 Corrective/Preventive Order
Form
929- Vehicles Maintenance Form Per order
O002 Corrective/Preventive Order
Form

Business Process Blueprint Plant Maintenance Version 1.0 Page 56 of 78


Business Blueprint
PM – Plant Maintenance

4.14 Authorization
Authorizations
Data Objects
ID Authorization (Sales Order / TA Reason # of employees
code)
 Plan the work
order
 Release the work
order
 Follow up
929- Maintenance
Maintennace Planner Activities
A001
 Completion
Confirmation
 Technical
Completion of
Order

Notification controller  Create


929- notification
A003

4.15 Change Impact Summary


N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 57 of 78


Business Blueprint
PM – Plant Maintenance

5 Preventive Maintenance (930)


5.1 Business Process Diagrams
Preventive (Planned) Maintenance-Time based
Role Process
Master

Team
Data

Functional
Equipment BOM Catalogs Task List
Location

10.0 20.0
Review Maintenance Is Maintenance Frequency
Start
Requirements (Internal & different for various
External) operations

20.1 20.2
Create Strategy based Yes No Create Single Cycle
maintenance plan Maintenance plan
Maintenance Planner /
Fleet controller

30.0
Schedule Maintenance Plan
End No

50.0
40.0
120.0 Yes Automatic Creation of maintenance
Call date falls on run
Complete the order and the work order
date
notification

110.0
Enter Technical findings
60.0
The work order is planned
100.0 automatically
Confirm the work order

Yes
Maintenance

80.0
Executer

90.0 Execute
70.0
All Activities are Maintenance
Print Maintenance Order
Completed? order

No

Business Process Blueprint Plant Maintenance Version 1.0 Page 58 of 78


Business Blueprint
PM – Plant Maintenance

Preventive (Planned) Maintenance-Performance based


Role Process
Master

Team
Data

Functional
Equipment BOM Catalogs Task List
Location

10.0 20.0
Review Maintenance Is Maintenance Frequency
Start
Requirements (Internal & different for various
External) operations

20.1 20.2
Create Strategy based Yes No Create Single Cycle
maintenance plan Maintenance plan
Maintenance Planner /
Fleet controller

30.0 Measure
Schedule Maintenance Plan Document
End No

40.0 50.0
120.0 Targeted counter Yes Automatic Creation of maintenance
Complete the order and the reading reached on work order
notification run date

110.0
Enter Technical findings
60.0
The work order is planned
automatically
100.0
Confirm the work order

Yes
Maintenance
Executer

90.0
80.0 70.0
All Activities are
Execute Maintenance order Print Maintenance Order
Completed?

No

Business Process Blueprint Plant Maintenance Version 1.0 Page 59 of 78


Business Blueprint
PM – Plant Maintenance

5.2 Business Process Description


Preventive Maintenance is planned maintenance that is designed to improve equipment’s life and avoid
breakdowns on the plant

Types of Preventive Maintenance


 Time based
o Single cycle plan
o Strategy plan

 Performance based
o Single counter plan
o Strategy counter plan

 Multiple-counter plan

A maintenance plan will be created for individual equipment which operates independently of other
equipment or for a Functional location which may comprise several pieces of equipment.

Pre-defined task lists can be attached to maintenance plans, which will be consisting of the operations to
be carried out at the time of maintenance plan execution.

Process Characteristics
Process Trigger Call date/target measure document
Process Input Measure document
Process Output Preventive Maintenance order
Process Owner Maintenance department
Process Frequencies As per the Plan
Business Process Blueprint Plant Maintenance Version 1.0 Page 60 of 78
Business Blueprint
PM – Plant Maintenance

5.3 Process Step Detailed Requirements & Solution


Process Step Description
Measure GAP
Ref. to
Process Step of Description
ID Requirements Solution Description
Description successful (WRICEF
as applicable
delivery ID)
930- Maintain saved A maintenance strategy
001 Maintenance represents a rule for the
Strategies sequence of planned
maintenance and inspection
tasks. A maintenance
strategy contains the
maintenance packages that
define the cycle in which the
tasks must be performed, for
example, every two months,
every 5,000 km, every 500
operating hours. It contains
additional scheduling
parameters such as shift
factor, preliminary and
follow-up buffers, and
hierarchy. Maintenance
strategies are required in
strategy plans. Single cycle
plans do not use
maintenance strategies.
They only have one
maintenance cycle.
930- Entering a General saved A task list group combines
002 Task List one or more task lists
according to their logical
features.
930- Create a saved A list of maintenance tasks
003 Maintenance Plan to perform on maintenance
objects.
930- Schedule a scheduled When you schedule your
004 Maintenance Plan maintenance plan for the
(First Time first time, you trigger the
Scheduling) maintenance cycle. The
system uses the scheduling
information in the
maintenance plan to
calculate which maintenance
package is due next.

Business Process Blueprint Plant Maintenance Version 1.0 Page 61 of 78


Business Blueprint
PM – Plant Maintenance

930- Process-Created saved The maintenance order is


005 Maintenance Order used to collect all costs for a
for Preventive maintenance task and to
Maintenance debit the cost center that
incurred the costs using the
settlement functions in the
CO module (Controlling).
930- Goods Issue to posted After the order is released,
006 Maintenance Order the Maintenance Employee
prints the pick-list and picks
the spare parts according to
the order. The system
performs a goods issue
930- Create Purchase saved The purpose of this activity
007 Order from is to create the Purchase
Purchase Order for the purchase
Requisition in requisitions that are created
Maintenance Order for external services and
external operation in the
maintenance order.
930- Goods Receipt to posted Confirm the goods receipt of
008 Purchase Order external operation and non-
stock material.
930- Invoice Verification saved Send bill for the vendor
009 for Purchase Order
930- Show Costs on Display cost overview in
010 Maintenance Order maintenance order
930- Confirming a saved In this step, time
011 Maintenance Order confirmation would be
carried out for the
refurbishment order.

Business Process Blueprint Plant Maintenance Version 1.0 Page 62 of 78


Business Blueprint
PM – Plant Maintenance

930- Technically saved If an order has been


012 Completing a executed, it must be
Maintenance Order completed in the system.
This shows that the order
has been processed. In the
PM module, there are two
types of completion,
technical completion and
business completion.
Technical completion shows
that an order was technically
successful or it can be
viewed as technically
completed by Plant
Maintenance.
The following shows how
technical completion works
930- Settling the saved In this activity, you settle the
013 Maintenance Order actual costs of the
maintenance order to the
cost center, internal order or
asset under construction
930- Closing the saved In this activity, you complete
014 Maintenance Order the maintenance order.
- Business View Business completion takes
place when purchasing or
invoice verification has
posted outstanding invoices
for external services or
external materials for the
order and the order is then
settled via the settlement
functions in the CO
(Controlling) module.

5.4 Key Policies/Operational Decisions or Logic within the Process


NA

5.5 Integration Points


Integration Points
SAP
ID Integration Point Data Element Contacts
Component
1 Purchase Requisition MM
2 Goods Movement MM
3 Order Settlement CO

Business Process Blueprint Plant Maintenance Version 1.0 Page 63 of 78


Business Blueprint
PM – Plant Maintenance

5.6 Potential Future Process Improvements (out of scope for this


implementation)
NA

5.7 Organization Structure Considerations


Organizational units related to the process:
 Maintenance/Planning Plants
o 1000 NOVA Water Production Plant
o 1002 Vehicle Workshop
 Planner groups
NOVA Water Production Plant Planner Groups are:
o 100 Mechanical Group
o 200 Electrical Group
o 300 Blow Molding & Injection
o 400 General Repair Group
o 500 ACs

Vehicle Workshop Planner Groups are:


o 600 Vehicles

5.8 Master Data Considerations (including all relevant data relationships)


Master data element that will be used with the process:
 Functional Location
 Equipment
 Work Center
 Material
 Measure point
 Measure document
 Maintenance strategy
 Task list

5.9 Configuration Considerations


Maintenance Notification will not be used in preventive maintenance
Maintenance Order type will be used in Preventive Maintenance are:
 PM02: Factory Preventive Maintenance.
 VM02: Vehicle Preventive Maintenance.
PM Activity type per preventive maintenance order type:
 PM02: Factory Preventive Maintenance.
o 100 Mechanical Maintenance
o 200 Electrical Maintenance
o 300 Blow Molding & Injection Maintenance
o 400 General Repair Maintenance
o 500 ACs Maintenance.

Business Process Blueprint Plant Maintenance Version 1.0 Page 64 of 78


Business Blueprint
PM – Plant Maintenance

5.10 Reporting (operational and analytical)


Reporting
Report Type
WRICEF
Description (ABAP, BI, Data Elements Relevant KPI Owner
ID
BOBJ)
930- Order List
R001
930- Cost Analysis
R002
930- Material
R003 availability
Scheduling
930-
R004
Overview and
simulation
930- Scheduling
R005 Overview

5.11 Interfaces
N/A

5.12 Enhancements
N/A

5.13 Output (e.g. forms)


Output/ Forms
Output
Type
WRICEF Data Object (Sales
Description (Form, Frequency Volumes Owner
ID Order)
EDI,
etc.)
930- Factory Maintenance Form Per order
O001 Corrective/Preventive Order(PM01,PM02)
Form
930- Vehicles Maintenance Form Per order
O002 Corrective/Preventive Order(VM01/VM02)
Form

Business Process Blueprint Plant Maintenance Version 1.0 Page 65 of 78


Business Blueprint
PM – Plant Maintenance

5.14 Authorization
Authorizations
Data Objects
ID Authorization Reason # of employees
(Process Step)
Maintenance Planner  Create Maintenance Strategies
 Create Maintenance Plan
 Create Measurement
documents
 Schedule Maintenance Plans
 Background Scheduling of
930-
A001 Maintenance Plan
 Usage Decision for closing the
Inspection
 Completion Confirmation
 Technical Completion of Order
(TECO)

5.15 Change Impact Summary


N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 66 of 78


Business Blueprint
PM – Plant Maintenance

6 Spare Parts Refurbishment (887)


6.1 Business Process Diagrams
Refurbishment Maintenance
Role Process
Notification Master

(Requester) Team
Data

Serial Material
Equipment BOM Permits
number Number

10.0
Initiator

Request for
Start
Refurbishment
Maintenance

20.2
20.0 No Subcontracting
Internal Processing Cycle
Maintenance Planner

YES

20.1 40.0
30.0 80.0 90.0
Create Release
Refurbishment Confirm work Complete the
Refurbishment Refurbishment
Order Planning Order order
Order Order

No
Executer

50.0 YES
60.0 70.0
Print
Order All Activities are
Maintenance
Execution Completed?
order
Departments

60.1 60.2 100.0


Other

110.0
MM Goods MM Goods CO Order
Order Close
Issue Receipt Settlement

Business Process Blueprint Plant Maintenance Version 1.0 Page 67 of 78


Business Blueprint
PM – Plant Maintenance

6.2 Business Process Description


This process covers the refurbishment cycle that aims to increase the value of the defective spare parts
and equipment that exists in the warehouse and makes these defective components ready to be used
again.

In case of external processing for refurbishment maintenance Subcontracting process will be used as
shown in the next process
Process Characteristics
Process Trigger Many defective parts need to be repair
Process Input Refurbishment order
Process Output Refurbishment order
Process Owner Maintenance department
Process Volumes
Process Frequencies Upon request

6.3 Process Step Detailed Requirements & Solution


Process Step Description
Measure GAP
Ref. to
Process Step of Description
ID Requirements Solution Description
Description successful (WRICEF
as applicable
delivery ID)
887- Create standard Saved In this step, the maintenance
001 maintenance order order would be created with
the defective equipment.
887- Remove Defective The defective equipment
002 Pump would be dismantled from
the functional location.
887- Return Defective Material This step is used to return
003 Pump to document the defective pump into
Warehouse posted warehouse.
887- Goods Issue with Material After the order is released,
004 New Pump with document the Maintenance Employee
Serial Number posted prints the pick-list and picks
the spare parts according to
the order. The system
performs a goods issue.
887- Activating Saved In this step, the equipment
005 Equipment View for view is activated, and this
New Pump and equipment is installed
Install according to functional
location.

Business Process Blueprint Plant Maintenance Version 1.0 Page 68 of 78


Business Blueprint
PM – Plant Maintenance

887- Creating Saved In this step, a refurbishment


006 Refurbishment order would be created for
order the defective spare part and
the order would be released.
887- Material Material After the order is released,
007 Withdrawal for document the Maintenance Employee
Refurbishment posted prints the pick-list and picks
the spare parts according to
the order. The system
performs a goods issue.
887- Time Confirmation Saved In this step, time
008 confirmation would be
carried out for the
refurbishment order.
887- G/R for Material Return the refurbishment
009 Refurbishment document material to the warehouse,
order posted and the valuation of the
spare part would be
updated.
887- Check material Now that you have posted
010 stock the goods receipt, you can
now check the material
stock and compare it with
the initial situation
887- Display Material Display the different
011 value valuation price for the spare
part.
887- Technically Saved The refurbishment order
012 Completing order would be completed
technically.
887- Settling Order Saved The refurbishment order
013 would be settled
887- Closing Order Saved In this step, the
014 (Optional) refurbishment order would
be closed.

6.4 Key Policies/Operational Decisions or Logic within the Process


NA

Business Process Blueprint Plant Maintenance Version 1.0 Page 69 of 78


Business Blueprint
PM – Plant Maintenance

6.5 Integration Points


Integration Points
Integration SAP
ID Data Element Contacts
Point Component
1 Goods issue MM
2 Order CO
Settlement

6.6 Potential Future Process Improvements (out of scope for this


implementation)
NA

6.7 Organization Structure Considerations


Organizational units related to the process:
 Maintenance/Planning Plants
o 1000 NOVA Water Production Plant
o 1002 Vehicle Workshop
 Planner groups
NOVA Water Production Plant Planner Groups are:
o 100 Mechanical Group
o 200 Electrical Group
o 300 Blow Molding & Injection
o 400 General Repair Group
o 500 ACs

Vehicle Workshop Planner Groups are:


o 600 Vehicles

6.8 Master Data Considerations (including all relevant data relationships)


Master data element that will be used with the process:
 Equipment
 Work Center
 Material
 Serial Number

6.9 System Configuration Considerations


Maintenance Notification will not be used in refurbishment maintenance

Maintenance Order type will be used in Refurbishment Maintenance are:


 PM04: Refurbishment Order
 VM04: Vehicle Refurbishment Order.

Business Process Blueprint Plant Maintenance Version 1.0 Page 70 of 78


Business Blueprint
PM – Plant Maintenance
PM Activity type per operational maintenance order types:
 PM04: Corrective Maintenance
o 100 Mechanical Maintenance
o 200 Electrical Maintenance
o 300 Blow Molding & Injection Maintenance
o 400 General Repair Maintenance
o 500 ACs Maintenance.
User status for Maintenance orders (PM04, and VM04):
 Created
 Pending:
Reasons for pending will be as below:
o Waiting for spare parts
o Waiting for external technician
o Waiting for fabricating
 In process
 Cancelled
 Completed

6.10 Reporting (operational and analytical)


Reporting
Report Type
WRICEF
Description (ABAP, BI, Data Elements Relevant KPI Owner
ID
BOBJ)
887- Order List
R001
887- Cost Analysis
R002
887- Material
R003 availability

6.11 Interfaces
N/A

6.12 Enhancements
N/A

6.13 Output (e.g. forms)


Output/ Forms
Output
WRICEF Data Object Type
Description Frequency Volumes Owner
ID (Sales Order) (Form,
EDI, etc.)
NA

Business Process Blueprint Plant Maintenance Version 1.0 Page 71 of 78


Business Blueprint
PM – Plant Maintenance

6.14 Authorization

Authorizations
Data Objects
ID Authorization (Sales Order / TA Reason # of employees
code)
Maintenance Planner  Plan the work
order
 Release the work
order
 Follow up
Maintenance
887- Activities
A001
 Completion
Confirmation
 Technical
Completion of
Order

6.15 Change Impact Summary


N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 72 of 78


Business Blueprint
PM – Plant Maintenance

7 Spare Parts Refurbishment via Subcontracting (ZPM1)


7.1 Business Process Diagrams

Subcontracting Maintenance
Role Process
Notification Master

(Requester) Team
Data

Serial Material
Equipment BOM Permits
number Number

10.0
Initiator

Request for
Start
Refurbishment
Maintenance

20.2
20.0
YES Refurbishment
Internal Processing
Maintenance Planner

Cycle

NO

20.1 40.0 50.0


30.0 110.0
Create Assign Release
Maintenance Complete the
Refurbishment Subcontracting Maintenance
Order Planning order
order material Order
Departments

60.0 100.0
70.0 80.0 120.0
Other

MM Purchase MM Goods 130.0


MM Goods MM Delivery to CO Order
Requisition Receipt from Order Close
Issue subcontractor Settlement
and PO subcontractor
Subcontractor

90.0
Execution by
Subcontractor

Business Process Blueprint Plant Maintenance Version 1.0 Page 73 of 78


Business Blueprint
PM – Plant Maintenance

7.2 Business Process Description


Subcontracting cycle is used in case of defective equipment need to be repaired externally. Ordinary
maintenance order is created with control key PM02 and subcontracting indicator.

Process Characteristics
Process Trigger Many defective parts need to be repaired externally
Process Input Refurbishment order
Process Output Refurbishment order
Process Owner Maintenance department
Process Volumes
Process Frequencies Upon request

7.3 Process Step Detailed Requirements & Solution


Process Step Description
Measure GAP
Ref. to
Process Step of Description
ID Requirements Solution Description
Description successful (WRICEF
as applicable
delivery ID)
ZPM1- Create standard Saved In this step, the
001 maintenance order maintenance order would
be created with the
defective equipment.
ZPM1- Remove Defective The defective equipment
002 Pump would be dismantled from
the functional location.
ZPM1- Return Defective Material This step is used to return
003 Pump to document the defective pump into
Warehouse posted warehouse.
ZPM1- Goods Issue with Material After the order is released,
004 New Pump with document the Maintenance
Serial Number posted Employee prints the pick-
list and picks the spare
parts according to the
order. The system
performs a goods issue.
ZPM1- Activating Saved In this step, the equipment
005 Equipment View view is activated, and this
for New Pump and equipment is installed
Install according to functional
location.

Business Process Blueprint Plant Maintenance Version 1.0 Page 74 of 78


Business Blueprint
PM – Plant Maintenance
ZPM1- Creating Saved Create maintenance order
006 standared order to start execute
subcontracting
maintenance activity
ZPM1- Assign Assign the defective
007 Subcontracting material code to
material maintenance order as a
subcontracting material
ZPM1- Create Purchase Material The purpose of this activity
008 Order from document is to create the Purchase
Purchase posted Order for the purchase
Requisition in requisitions that are
Maintenance created for external
Order services and external
operation in the
maintenance order.
ZPM1- Goods Issue for Material After the PO is approved,
009 Subcontracting document defective material is sent
material posted to subcontractor to
execute maintenance
activities. The system
performs a goods issue.
ZPM1- Subcontracting Material Subcontracting material is
010 material delavery document delivered to the
to Subcontractor posted subcontractor
ZPM1- G/R form Material Return the repaired
011 Subcontractor document material from the
posted subcontractor to the
warehouse, and the
valuation of the spare part
would be updated.
ZPM1- Check material Now that you have posted
012 stock the goods receipt, you can
now check the material
stock and compare it with
the initial situation
ZPM1- Display Material Display the different
013 value valuation price for the
spare part.
ZPM1- Time confirmation Saved In this step, time
014 confirmation would be
carried out for the
refurbishment order.
ZPM1- Technically Saved The refurbishment order
015 Completing order would be completed
technically.

Business Process Blueprint Plant Maintenance Version 1.0 Page 75 of 78


Business Blueprint
PM – Plant Maintenance
ZPM1- Settling Order Saved The refurbishment order
016 would be settled
ZPM1- Closing Order Saved In this step, the
017 (Optional) refurbishment order would
be closed.

7.4 Key Policies/Operational Decisions or Logic within the Process

7.5 Integration Points


Integration Points
Integration SAP
ID Data Element Contacts
Point Component
1 Purchase MM
Requisition
2 Goods MM
Movement
3 Order CO
Settlement

7.6 Potential Future Process Improvements (out of scope for this


implementation)
NA

7.7 Organization Structure Considerations


Organizational units related to the process:
 Maintenance/Planning Plants
o 1000 NOVA Water Production Plant
o 1002 Vehicle Workshop
 Planner groups
NOVA Water Production Plant Planner Groups are:
o 100 Mechanical Group
o 200 Electrical Group
o 300 Blow Molding & Injection
o 400 General Repair Group
o 500 ACs

Vehicle Workshop Planner Groups are:


o 600 Vehicles

Business Process Blueprint Plant Maintenance Version 1.0 Page 76 of 78


Business Blueprint
PM – Plant Maintenance

7.8 Master Data Considerations (including all relevant data relationships)


Master data element that will be used with the process:
 Equipment
 Work Center
 Material
 Serial Number

7.9 System Configuration Considerations


Maintenance Notification will not be used in refurbishment maintenance

Maintenance Order type will be used in Refurbishment Maintenance are:


 PM04: Refurbishment Order
 VM04: Vehicle Refurbishment Order

PM Activity type per operational maintenance order types:


 PM04: Corrective Maintenance
o 100 Mechanical Maintenance
o 200 Electrical Maintenance
o 300 Blow Molding & Injection Maintenance
o 400 General Repair Maintenance
o 500 ACs Maintenance.

7.10 Reporting (operational and analytical)


Reporting
Report Type
WRICEF
Description (ABAP, BI, Data Elements Relevant KPI Owner
ID
BOBJ)
ZPM1- Order List
R001
ZPM1- Cost Analysis
R002
ZPM1- Material
R003 availability

7.11 Interfaces
N/A

7.12 Enhancements
N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 77 of 78


Business Blueprint
PM – Plant Maintenance

7.13 Output (e.g. forms)


Output/ Forms
Output
WRICEF Data Object Type
Description Frequency Volumes Owner
ID (Sales Order) (Form,
EDI, etc.)
NA

7.14 Authorization
Authorizations
Data Objects
ID Authorization (Sales Order / TA Reason # of employees
code)
Maintenance Planner  Plan the work
order
 Release the work
order
 Follow up
ZPM1- Maintenance
A001 Activities
 Completion
Confirmation
 Technical
Completion of
Order

7.15 Change Impact Summary


N/A

Business Process Blueprint Plant Maintenance Version 1.0 Page 78 of 78

Anda mungkin juga menyukai