SAP PM MODULE

BUSINESS
PROCESS
The need for Information
Vision
An Integrated, Flexible and Standardised Information
Systems architecture to position towards
fundamental competitive advantage
Current Reality
Function based Organisation, Multiple stand alone packages,
Time lag between market realities and decision making
SAP
for Enterprise-wide
Transformation.
SAP R/3 The Integrated Enterprise
SAP
R/3
Client / Server
ABAP/4
FI
Financial
Accounting
CO
Controlling
AM
Fixed Assets
Mgmt.
PS
Project
System
IM
Investment Mgmt
IS-Oil
MM
Materials
Mgmt.
SD
Sales &
Distribution
PP
Production
Planning
PM
Plant Main-
tenance
QM
Quality
Manage-
ment
EC
Enterprise
Controlling
LDM
Lifecycle
Data Mgmt
CIN
Navigating SAP R/3
Navigation Topics
Logging On
SAP Window components
Using the Navigation Area
Transaction Codes
Role Based Menu
Standard Tool Bar
SAP Easy Access
User Settings
Messages
Online Help use
Logging on
Required Fields
Client
User
Password
Language
The SAP Window
Status Bar
Title Bar
Standard Tool Bar
Menu Bar
SAP System ID
Server
Insert/Overtype Indicator
Screen Header
Screen Body
Application Tool Bar
Screen Banner
Using the Navigation Area
You can expand and
collapse menus in the
navigation area by
choosing the dropdown
arrows to the left of the
menu items, as in the
example below

To open an application in
the navigation area
Double-click its node
Transaction Codes
A transaction code can be entered in the Command field.
If you precede the transaction code
with /n then the transaction is the
next screen opened in the current session.
If you precede the transaction code
with /o then a new session is opened
for the transaction. This means you then have multiple sessions.

To start a transaction in SAP 4.6, there are 4 options:
Position the cursor on the required transaction in the tree structure and press
enter
Double-click on the required transaction in the tree structure
Position the cursor on the required transaction in the tree structure and select
Edit Execute (or press F2)
Expand the command field and enter the transaction code
Standard Toolbar
The Standard Toolbar contains the Command field and the
standard SAP Toolbar buttons.
Command Field: The Command field is used to enter transaction
codes that take you directly to a system task without using
menus.

Button Keyboard Shortcut Description Button Keyboard Shortcut Description
Enter Key Enter/Continue Ctrl + Page Up First page
Ctrl + S Save to database Page Up Previous page
F3 Back Page Down Next page
Shift + F3 Exit System Task Ctrl + Page Down Last page
F12 Cancel None Create New session
Ctrl + P Print None Create shortcut on Desktop
Ctrl + F Find F1 F1 Help
Ctrl + G Find next Alt + F12 Customize Local Layout
SAP Easy Access Settings
Users can set how SAP displays the Menu by choosing Extras Settings. Here,
you can specify whether:
Your favorites should appear before or after the menu
Only your favorites, and not the menu, should appear
The SAP Easy Access graphic should appear on the right-hand side of the
screen.
Technical names of menu options should appear in the navigation area

User Settings
Users can maintain their own settings by choosing System User Profile Own
Data
Defaults
Change default printer, language, and date and decimal display formats.
Parameters
Allow user to create default information for frequently used fields.
Messages appear either in the status bar or in a pop-up window, depending on
user settings
Messages starting with:
E indicate an Error message
W indicate a Warning message
Messages not beginning with an E or a W are simply Information
messages
Required fields are denoted by a check mark
Messages
Using Online Help
Field Level Help
Used to describe what a
currently selected field is
designed to do.
Click on the Help icon or F1.

Example:
Find definition of Material number
Click Material field
Click Help button or press F1
key
Click Cancel button to return
to the screen
SAP Mail system is used to send a mail to other users of SAP in.
The recipient is identified by User ID of SAP e.g., STR_PM3, STR-PM1,.,
SAP Mail can be used for sending information regarding a Notification,
order, equipment etc., through SAP screen or
through the SAP menu by tcode SBWP (Sap Business work place) for a
normal message.
Procedure :
In a SAP screen Go to
services for object .
In the following screen click on
Send icon.
SAP Mail
Enter message
If the mail is required to
be attended immediately
check Express mail
Enter recepient
Click Send
or use tcode sbwp and
follow as detailed below
SAP Mail
Plant Maintenance
Overview
PM-01 Organization Structure
PM-01-01 Organization Structure

Section
Organization Structure
Maintenance Planning Plant

Maintenance Plant
Aeration
BioSludge
Air Comp
System
H2SO4
Transfer
Boiler
Blowers
Functional
Locations
Organization Structuring 1/5
A grouping of legal,
organizational, business
and/or administrative
units with a common
purpose. Single database
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Organisation Structuring 2/5
Represents an independent
accounting unit within a
client. Each company code
has its own balance sheet
and its own profit and loss
statement.
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Organisation Structuring 3/5
Operational unit within
a company code.

Material Valuation
Inventory Management
Material Master

Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Organisation Structuring 4/5
Maintenance Objects
Work Centres
Same as Plant
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Organisation Structuring 5/5
Planner Groups

Task lists
Maintenance Plans
Order Creation
Resource Planning
Work Scheduling

Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Definition of the Organization Elements
Company Code: The smallest organizational unit for which a complete
self-contained set of accounts can be drawn up for purposes of external
reporting.
Maintenance Plant: Plant, in which the technical objects of a company
are installed.
The planning responsibility for a maintenance plant is defined by using
a planning plant. Maintenance plants are assigned to maintenance
planning plants.
Maintenance Planning Plant: Plant in which maintenance tasks are
planned and prepared.These tasks can relate to technical objects in
your own plant or in other plants.Maintenance planning plants are
normal plants that are indicated as maintenance planning plants in
Customizing. Maintenance plants, which do not plan their own
maintenance tasks, are assigned to the planning plants. Planning is
performed for the maintenance plants in the planning plants entered.

PM-02 Master Data
PM-02-01 Functional Location

Section
A functional location is an element in a technical structure, representing an
area/spatial/functional of a Plant at which
Equipment/s can be installed.
PM Functional Location
Structure Indicator
Edit Mask xxx-xxx-xxx-xxxx-xxx-xxxxx
Hierarchy levels 1 2 3 4 5 6
LEVEL 1

LEVEL 2

LEVEL 3

LEVEL 4

LEVEL5

LEVEL6

LEVEL 7
Functional Locations-Criteria
Criteria for Functional Location :
Execution of Maintenance Tasks
Recording of Maintenance Task
Data Collection over long periods of time
Cost Monitoring by Area
What affect do the Usage Condition have on the
likelihood of Damage to the installed aggregates.
Used normally for the object which are not movable.
Understanding the Transaction
PM-03-02-01 Master Data Functional Location
Functional Location Structure using Tcode IH01
List Display of Functional location using Tcode IH06
PM-02 Master Data
PM-02-02 Equipment

Section
Equipment-Criteria

Criteria of Equipments :

Management of Individual Data
Recording of Maintenance tasks
Object based recording of costs
Evaluation of technical data
Recording of Usage Times

Equipment Usage List
Understanding the Transaction
PM-03-02-02 Master Data Equipments
Equipment Structure using Tcode IH03
PM-02 Master Data
PM-02-03 Measuring Points

Section
Measuring Points
Measuring points in the R/3 System describe the physical and/or logical
locations at which a condition is described, (for example, the compressor
discharge pressure).
Measuring points are located on technical objects ie. on pieces of
equipment or functional locations.
Measuring Point can be either a parameter value or a counter.
Measurement Readings are entered for the measurement point with
reference to a specific time.
Notifications can be generated automatically if the value of the measuring
reading exceeds the range specified in measuring point.
Measurement and counter readings are stored in the system in the form
of measurement documents. These documents are the basis for
performance-based maintenance planning

Understanding the Transaction
PM-03-02-03 Measuring Points
Display Measuring Point using Tcode IK03
Create Measurement Document using Tcode IK11
PM-02 Master Data
PM2-02-04 Bill of Material(BOM)
Section
Bill of material
Bill of Materials (BOMs)
A complete, formally structured list of the components making up a technical object
The list contains the individual components together with their quantity and unit of measure
The components can be stock or non-stock spares or assemblies

Purpose
Material/spare parts planning
to assign materials/spare parts to a maintenance order.
Locating malfunctions
to locate the malfunction in the piece of equipment or in its bill of material for a
maintenance notification.
Material assignment
to assign material to the individual operations of a task list.
Bill of material for equipment
10
Equipment - 10006767
Centrifugal Pump
Equipment BOM
Casing type A 100-100 1 PC
PC
PC
PC
PC
PC
PC
PC
PC
30
40
50
60
70
80
90
20
Shaft
Sleeve
Bearing - A
Bearing - B
Wear Ring A
Wear Ring B
Impeller
Seal 100-300
100-400
100-500
100-600
100-700
100-800
100-900
100-200
1
1
2
1
1
4
1
2
Understanding the Transaction
PM-03-02-04 BOM
Display Equipment BOM using Tcode IB03
Display Functional Location BOM using Tcode IB13
PM-02 Master Data
PM-02-05 General task List

Section
THESE TASKS ARE , FOR EXAMPLE :-
INSPECTIONS - Determining the actual condition.
MAINTENANCE - Maintaining the ideal condition.
REPAIRS - Restoring the ideal condition.
SEQUENCE OF INDIVIDUAL MAINTENANCE TASKS
WHICH REPEATEDLY HAVE TO BE PERFORMED ON A
MACHINE OR AT A SPECIFIC AREA.
Plant Maintenance task list Check list
Task List
Maintenance task lists describe a sequence of individual maintenance activities
which must be performed repeatedly within a company. The functions for
creating data in equipment task lists, functional location task lists and general
maintenance task lists are very similar and will therefore be dealt with jointly in
this section.
1. You create operations and, where necessary, sub-operations and enter detail
data for internal or external processing.
2. You can include user data in the operations or sub-operations, as required.
3. You can assign the following objects to the operations:
Material components
Production resources/tools
Maintenance packages
Inspection characteristics
You can arrange the operations according to time by
defining relationships.
You can perform a cost analysis.
Equipment 2
Equipment
Functional location
TL
Task
list
categories
FL1
Op. 1
Op. 2
Op. 3
FL2
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
TL TL
Equipment 1
TL
Task list categories
General task lists
Pumps
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
Cleaning
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
Task List Group Counter
Understanding the Transaction
PM-03-02-05 Task List
Display Equipment Task List using Tcode IA03
Cost Maintenance Task Lists using Tcode IA16
Material Where used list: Task List using Tcode IP62
PM-02 Master Data
PM-02-06 Maintenance Plan

Section
Types of Preventive Maintenance
2001

Performance-based Time-based
Preventive
Maintenance
Maintenance Plans
Maintenance plan
Single cycle plan Strategy plan Multiple counter plan
Time-based Performance-based
Maintenance Plans
Maintenance Plan Functions
Scheduling Period
























Scheduling data
Maintenance item
Maintenance plan












Order 901760
Cycle start Scheduling period
Schedule in future
displayed for the
specified scheduling
period

Planned dates
Orders
Scheduling period
1 year












Call Horizon

Maintenance item
Maintenance plan












Order 901760
Scheduling data
Cycle
start
Call date derived from
the call horizon
Planned date
Cycle 3 months = 90 days
Call horizon at 90% = 81 days
Shift Factor

Maintenance item
Maintenance plan
Scheduling data
Cycle start
Technical completion
30/07/2003
Planned date
Cycle 1 month
Shift factor 100%
Planned date
New planned date
30/07/2003(shifted by
100%)
Tolerances can be used in combination with Shift factors to control the
shifting of future planned dates
Cycle Modification Factor

Maintenance item
Maintenance plan
Scheduling data
Cycle start

Cycle modification
Factor

1.5
Planned date New planned date
Cycle
3 months 4.5 months
Scheduling Indicator
Scheduling Indicator




Scheduling data
Maintenance item
Maintenance plan
Time
1 month = 30 days
Time
Time-
key date
Time-
Factory cal.

Scheduling
indicator
Time key date
Falls due on exactly the
same date as per the cycle
Time Factory calendar
Falls due as per the cycle with
factory calendar as the
reference for calculating time
Cycle start
Cycle start
Cycle start
Deadline Monitoring

= Planned dates
Orders for the
next 90 days
Order
Deadline monitoring
Date of deadline
monitoring run












Order 901760
Cycle 1 month
Maintenance Packages Hierarchy

Same hierarchy levels
H1
H1
H
2
H1
Different hierarchy levels
Strategy
Strategy
All the packages are executed which fall due on the same date
The maintenance package with the higher hierarchy suppresses
the lower one when both packages fall due on the same date
Maintenance Strategy

Package definition
3 months
6 months
Maintenance Strategy
Scheduling indicator
Time
Time using key date
Time using Fact. calendar
Strategy unit
Shift factors
Tolerances
Factory calendar
Scheduling Parameters
Understanding the Transaction
PM-03-02-06 Maintenance Plan
Display Maintenance Plan using Tcode IP03
Schedule Maintenance Plan using Tcode IP10
Scheduling of Maintenance Plan using Tcode ZPMIP30
Maintenance Plan Cost Display using Tcode IP31
Maintenance Cycle Set using Tcode IP11Z
Add Multiple Counter Plan using Tcode IP43
Maintain Maintenance Strategies using Tcode IP11
Add Strategy control Plan using Tcode IP42
PM-02 Master Data
PM-02-07 Catalogs

Section
CATALOGS
CATALOG PROFILES
CATALOG TYPES AND
CATALOG CODE GROUPS
CODES AND DESCRIPTIONS
In PM, only the catalogs type 2,5,A,B,C is used.
Catalogs
CATALOG TYPE-(B)
(OBJECT PARTS)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -1/5
CATALOG CODE (2)
(TASKS)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -2/5
CATALOG CODE (C )
(DAMAGES)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -3/5
CATALOG CODE (5)
(CAUSES)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -4/5
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -5/5
CATALOG CODE (A)
(ACTIVITIES)
Understanding the Transaction
PM-03-02-07 Catalogs
Maintain Catalog using Tcode QS41
PM-02 Master Data
PM-02-08 Work Center

Section
Work center : An Organizational unit.

It defines where and by whom an operation is to be performed.
Work Center in PM Module will be :
Group of Persons for eg. Multi Disciplinary team / Electrical /
Mechanical / Instrumentation Team.
The work center is specified in master data of equipment or
functional location, maintenance item, task list header,
operations of task list, order header and order operations.
Work Centers in PM
Work Center Contents
Work Center : Main Functions
Understanding the Transaction
PM-03-02-08 Work Center
Display Work Center using Tcode IR03
PM-02 Master Data
PM-02-09 Warranties

Section
Warranties

Warranties define the scope of the services that a Vendor
should provide for a technical object in the event of damage or
problems for the validity period.
Warranties to pieces of equipment of functional locations.
Warranty in PM is :
Vendor Warrantee (for example, manufacturer or vendor
warranty)
Structure of Warranty


Warranty
header
Warranty type
Description
Classification
Warranty
items
Service activities
inclusive/exclusive
Warranty
counter
Counters , limits
Understanding the Transaction
PM-03-02-09 Warranties
Display Master Warranty using Tcode BGM3

PM-02 Master Data
PM-02-10 Classification and Permits
Section
Classification
Classification system uses characteristics & values to describe all
types equipment, and to group similar equipment in classes.
Classification helps in finding equipment more easily, using the
characteristics defined in them and values as search criteria.
This also helps in finding equipment with similar or identical
characteristics.
Classification
Type Centrifugal / Screw /Reciprocating
Capacity 50 m3/hr / 75 m3/hr / 100 m3/hr
RPM 975 / 1450 / 2900
Head 10 Mt / 20 Mts / 30 Mts
Stages 1 / 2 / 3
Fluid Oil / Water / Acids
Class PUMP
Type
Capacity
RPM
Head
Stages
Fluid
Assignment of a pump to
class pump
Assigned values
Type - Centrifugal
Capacity - 75 m3
RPM - 1450
Head - 10 mt
Stages - 1
Fluid - Water
Find a pump in Class PUMP with capacity =75
m3
Characteristics and Values
Class
Maintenance
Classification
Locating a pump
Permits (Technical Permits) / Process Permits
Understanding the Transaction
PM-03-02-10 Classification and Permits
Characteristics using Tcode CT04
Classes using Tcode CL02
Find objects in classes using Tcode CL30N
Maintain Permit using Tcode IPMD

Now, let us start
understanding what we
discussed, better with
Hands-on Practice using
the Exercise Sheet PM-
02-10.
Let us Get into Hands-
on right now
PM-03 General
Maintenance Processing
PM-03-01 Notification Processing
Section
PM Notification Structure
Object Information
The Object Information contains
Structural Data, Classification
Data, Previous Damage, number
of days to solve the problem,
Previous notification
created/completed for the
technical object, maintenance
plans and documents for the
object.
Maintenance Processing
Maintenance Notifications for
Reporting malfunctions, breakdowns
Requesting for maintenance
Documenting the activities performed
Recording technical findings
Technical history of an object gets updated upon
completion of notification.
Notification Types
Understanding the Transaction
PM-03-03-01 Notification Processing
Create PM Notification using Tcode IW21
Create PM Malfunction Report using Tcode IW24

PM-03 General Maintenance
Processing
PM-03-02 Order Processing
Section
Technical Info.
Breakdown
Causes,Activities
Object affected

PM Notification
What
When
Where

Technical
Information
Breakdown
Plant
PM Planning
PM Work Center
Completion
PM History
PM Order
Completion
Confirmation
1
3
4
5
Completion
6
8
2
Problem , Error
Malfunction,Request,
Activity
Execution
Material
Withdrawals
Utilities
Work steps
Requesting
a Task
PM Order creation
Execution plang.
Who
When, How long
What work steps
Account Assign.
Resources
Task Planning.
7
Damage Related Process Maintenance Flow
Maintenance Processing
Notification creation
Order
required ?
Order Creation
Order Execution Material withdrawal
Work
Clearance/permits
Technical Completion
Order Settlement
Notification Completion
Yes
No
Update technical history
PR creation
Tendering, PO
creation, GR at
stores and
transportation to
local storage as
per MM, OLM
procedure
PR release as per BDP

Business Completion
Maintenance Activity Types In Orders
Maintenance Order Processing
Elements of Maintenance Order
Order header
For example: Order Type, Dates,Plant, Main object,
Priority, Description, Maintenance Activity type
Object list
For example:- Functional Locations, Equipment
Maintenance Notifications, Assemblies.
Operation
For example: Work Center, Control key, Descriptions
Standard time, Activity type,
Material list For example: Material, Quantity, Storage Location
Production resources/tools
Settlement Rule
Costs
(Estimated / Planned / Actual)
Operations
Operations

Operation Work Center Control key Description Activity Type
0010
0020
0030
0040
0050
MECH
MECH
MECH
MECH
ELEC
PM01
PM01
PM01
PM01
PM01
Oil change
Drain oil
Change oil filter
Add new oil
Check cable
List of operations
MAINT
MAINT
Stock Material Process Flow

May
Component
assignment
Material
Reservation
Order
Release
Printing
Goods
issue
May
Automatic
availability
check
Availability
check
Order Release

Reservation effective,
can be withdrawn

Shop Papers can be printed

Confirmation possible

Goods movement possible
Effects of Order Release:
Order Debits after Settlement

Other Postings












Act. Costs > 0
Order Execution











Act. Costs > 0
Invoice receipts
Controlling
Postings,

Completion
Confirmations
Material
Withdrawals


Maintenance
Order









Order Settlement
After settlement actual
Cost on the Order is
ZERO
Order Processing Summary







Controlling






Plant Maintenance


Order







Order not Modifiable
Postings can be
made to the Order
Postings cannot
be
Made to Order
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Time
PM Order Costing
PM Order
Internal activity
Op. 10:- 3 hrs
Op. 20:- 1 hr
External processing
Op. 30:- EXTERN 1 hr.
Warehouse issue
2 pcs Material ABC
Rs. 500
Rs. 150
Rs. 300
Internal processing:-
External Services:-
Warehouse Issue:-
Total:-
Rs. 950
Costs
Settlement: - Fixed Amount OR percentage Distribution
Equipment 4011
Operation 010: 10h
Workcenter Mech


Operation 020: 3h
Workcenter Electrical
PM Order
WorkCenter
'Mech'
Work Center
Electrical
Material
Receiver
Activities :-
Mech. activity.
Elect. activity.
COST
CENTRE
COST CENTER
(MAINT)
PM Order settlement
Maintenance Processing Cycle
Action Logs
Order Hierarchy
If maintenance order consists of several independent steps whose
costs should be separated, order hierarchy can be used.
All sub-orders should be completed before a main order can be
completed.
Movement Types in PM
101 Goods Receipt from Vendor
102 Reversal of 101
261 Goods Issue from Warehouse to Maintenance Orders
262 Reversal of 261
201 Goods from Warehouse to Cost Center
511 Reversal of 201.
541 Goods to Vendor for Refurbishment
303 Transfer Posting to another plant / storage location
305 Receive material from another plant
Understanding the Transaction
PM-03-03-02 Order Processing
Create PM Create Order Processing Tcode IW31(Normal)
Create PM Create Order Processing Tcode IW31(Refurbishment)
Create PM Create PM Sub Order using Tcode IW36
Goods Withdrawal using Tcode MB1A
Completion Confirmation using Tcode Tcode IW41
Overall Completion Confirmation using Tcode IW42

PM-04 Refurbishment Cycle
PM-04-01 Refurbishment Cycle
Section
Refurbishment Processing
Types of Refurbishment

Refurbishment Order
OEM Repairs Central Workshop
Refurbishment cycle - OEM

Create N9
Notification
CreatePM60 type of
Maintenance Order
Create PR/PO
Uninstall
Equipment .
install at Vendors FL
Create Batch and
And send to stores with
movement type 202
Refurbishment Cycle .. contd

Send Equipment
To vendor
movement type 541
Receive Equipment (GR)
Settle & Close Order
Send equipment
To Function location
Movement type 261
Complete Order
Refurbishment cycle - Workshop

Uninstall
Equipment
Change Plant ,
Work Center and planner group.
Retain Cost Center of Asset
To Central Workshop
And send to stores with
movement type 202
Transfer Posing from
Asset to Workshop.
Movement type 303/305
Refurbishment Cycle .. contd

Create Refurbishment
Order
Replace defective parts
To Asset
Complete the order.
Settle to Asset
Cost Center
Transfer Posting from
Workshop to Asset
Refurbishment Cycle .. contd

Send Equipment
From stores to F.
Movement type 201
Install Equipment
Create
Notification
N9
IH01or IW21
Create
Purchase
Requisition
ME51N
Create &
release
Service entry
sheet
ML81N
Change Equipment
data & Install at
original location
IE02
Stores to
Functional
location
MB1A (201)
Vendor to
Company after
repair
MB1B (542)
Send to
vendor
MB1B(541)
Release
Purchase
Requisition
ME54
Maintenance
order for
repair PM60
IW31

Create a
BATCH
MSC1N
Transferring
to Stores
MB1A (202)
Release
Purchase order
ME28
Transaction code XXX
Refurbishment cycle for repair at OEM/External
Dismantle
equipment &
install at Repair
Location
IE02
Create Purchase
Order
ME21N
Maintenance
order
Completion
IW32 / MIGO /
IW41 / TECO
Complete
Notification
IW22
323
Understanding the Transaction
PM-03-04-01
Create PM Create Order Processing Tcode IW31(Refurbishment)
Goods Back to Stores using Tcode MB1A
Goods Transfer Posting Tcode MB1B
Stock Overview Tcode MMBE
Completion Confirmation using Tcode Tcode IW41
Overall Completion Confirmation using Tcode IW42

PM-05 Work Clearance
Management
PM-05-01 WCM
Section
WCM
Reasons for Work Clearance Management : -

Maintenance Crews require safety measures.
Maintenance activity need to be performed while the systems are
operational
Work related measure which require special health and safety measure
ie. Controlling and monitoring lockout and tagout of various
equipments.

WCM and Maintenance Process
WCM
WCM Architecture




The work clearance application represents the safety certificate especially for
lockout/tagout.
In Plant, we will use WCA for getting prior approval to carry out any maintenance
job that requires WCM.
Two types of WCA :
Hot job/Cold Job - Do not require WCD
Tagout - Requires WCD
The work clearance document describes lockout/tagout. It contains a list of the
technical objects in a technical system to be tagged or monitored. It controls the
physical blocking and signposting of the technical objects affected. It also
contains a detailed description of how the system should be isolated.
WCM Architecture
WCM Model
WCM Permit
WCM type permit to be attached to the order for initiating WCM
WCA contains approvals to be granted for job execution
WCD contains approvals to be granted to ensure safe working
conditions.
Phases and Roles
Phases / Roles
Order
Work Clearance
Application
Create Order Order Creator
Work Clearance
Application
Work Clearance
Document
Approve / Perform
Tagout
Various concerened
agencies like control
room, electrical,
mechanical, safety
Competent Authority
Approve Work
Specify Objects
Containing Tagout
Order Creator
Application for
executing the
above order
Order Creator
Work Clearance
Document
WCM Objects Phase/Proces
s
Carried out by
WCM Process
1. A Maintenance Executives (maintenance in-charge, sectional heads) creates a
maintenance Order
2. If the job requires work clearance Maintenance Executives creates the WCA for
the order and requests the approval from competent authority to perform the job.
3. He also creates / copies from a template a Work Clearance Document. The WCD
contains details the tagging/un-tagging conditions of all the equipment / functional
locations / any other object (even w/o master data) which need to be tagged to
carry out the above maintenance work.
4. WCA created above is approved by the competent authority giving the clearance
for executing the maintenance activity.
5. At the time of actual execution, the tag out / lockout of the equipment mentioned
in the WCD is approved by various concerned agencies like control room,
electrical, mechanical, safety and their status is maintained in the system.
6. Any conflict in the status of any of the specified equipment / functional location
is prompted by the system.

WCM Process
Phases / Roles

Order (after
tagging)
Order
Labour Release
Maintenance In-
charge / Executor
Work Clearance
Document
Work Clearance
Application
Technical complete
the order
Maintenance Incharge
Perform Un-
Tagging
Closed Approving authority
Confirm that work
in the order is
comp
Maintenance
Executive
Order
WCM Objects Phase/Proces
s
Carried out by
WCM Process
6. When Tagging has been performed, the maintenance In charge can release the
order ( Labor release). Order release can take place independently of this.
7. After the work has been carried out and tag-out/log-out is no longer required, the
maintenance executive sets the status Work complete for the order. Technical
completion is possible only on WCD completion.

WCA Status Sequence
WCD Structure
WCD
Enter all technical objects that are to be processed using tag-out /
logout. The WCD may include equipment, functional locations and
items not maintained in the R3 system.
The WCD contains the detailed description of how the system should
be isolated.
The WCD controls the physical isolation and placing of tags on
affected technical objects (items).


WCD
The WCD template is used as a copy model when creating work
clearance documents.The work clearance document template itself
cannot be used to perform lockout/tag-out. Therefore, it cannot be
tagged/untagged or assigned. With template, the work clearance
documents for complex structures of technical systems do not
always have to be recreated.
The operational cycle is divided into the following operational
phases:
Tagging
Temporary un-tagging
Un-tagging
In the operational cycle, the items in an operational work clearance
document run through several statuses for each operational phase in
a specific sequence.


WCD Items
Operational Cycle
Operation Group
The WCD items defines the technical objects which need isolation for
lockout/tagout.
Operation condition gives the detailed description of conditions /
parameters for technical object (open /closed)
Each operation condition is valid for tagging / untagging.
Operational group is a logical grouping of operation conditions
designed to minimize the conflict.
For a technical object to be tagged / untagged, the system checks if
this objects is already a reference object in a processed Operational
WCD. A technical object cannot have different operational
conditions.

Operation Protection/Conflict Management
Protection which ensures that a technical object, which is managed as an item in an
operational work clearance document, can only be tagged/untagged from certain
Operation WCDs.
The operational protection can be used to protect the un-tagging of a position of
the operational work clearance document against other operational work clearance
documents.
The operational protection can be used to create protected areas. A protected area
is defined using the following criteria:
Operational protection of items in operational work clearance documents that
represent technical objects
Direct linking of operational work clearance documents using superior work
clearance applications
A technical object with operational protection can be tagged/untagged within the
protected area. However, it is not possible to tag/un-tag the technical object
outside of the protected area.

PM-06 Calibration Cycle
PM-06-01 Calibration Cycle
Section
Calibration Processing Cycle
Create Measuring Point
Classification
Assign to Measuring Point List
Calibration
plan
Assign Measuring
List
to task List
Calibration Order
Enter Readings
Calibration Cycle
Create Measuring point of Category C for each calibration value.
Assign Measurement position for calibration value.
Assign Measuring Point to Task list.
Create maintenance plan wrt to calibration equipment and task list.
Schedule the maintenance plan and release order
Enter the measurement reading for the equipment

Eg for a Diff pressure flow meter with pressure and temperature
corrections and calibration check for 0,25,50,75 and 100% values, 5
measuring points for each parameter ie. totally 15 measuring point
exists for the meter.

Understanding the Transaction
PM-03-06-Calibration cycle
Create measuring point IK01.
Create Measuring reading t entry list IK31.
Create Equipment task list IA01
Create measuring plan IP41
Release Order IW32.
Enter measuring reading IK34
PM-07 PMIS
PM-07-01 PMIS
Section
Noti-
fication
Work
Order
Objects Downtime
Costs
MTBR
Info Database
Reporting and Analysis
Apply
Noti-
fication
Equip-
ment
Maintenance Process
Info Database
H
i
s
t
o
r
y
Graphic
ABC analysis
Classification
TOOLBOX
PM Information system
Plant Maintenance Reports
Analysis of Maintenance Order Costs as per internal labor , material
, services cost.
Monitoring of Maintenance order compliance / back logs for
Planned / unplanned / emergency order.
Break down analysis as per cause , damage and part failure.
Manufacturer wise analysis of Equipment maintenance.
Material Consumption report for Equipment.
Mean time to repair and mean time between failure reports for
Equipments.
Calibration test reports for Instruments.
Measuring value parameters for equipment
Understanding the Transaction
PM-03-07-PMIS
Manufacturer Analysis using Tcode MCI2
Planner Group Analysis MCI4
Object Analysis using Tcode MCI6
Cost Analysis using Tcode MCI8
Mean Time Between Repair using Tcode MCJB/MCJC
Thank You