Anda di halaman 1dari 163

Business Consulting Services

SAP PM Module Training

SAP R/3

PLANT MAINTENANCE SYSTEM

Presentation Title | Confidential | Document ID

| Aug 18, 2015

PLANT MAINTENANCE SYSTEM

I. MANAGING MASTERS
II. MANAGING MAINTENANCE PROCESSES
III. MANAGING REPORTS

Presentation Title | Confidential | Document ID

| Aug 18, 2015

I. MANAGING MASTERS

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

CONTENTS OF MAINTENANCE
OF MASTERS

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Plant
Main Planner Group
Plant Section
Main Work Center
Cost Center /Internal Order
Category
Company Code
Strategy
UOM

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

CONTENTS OF MAINTENANCE
OF MASTERS

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Function Location
Structure
Function Location Category
Plant

| Aug 18, 2015

FUNCTIONAL LOCATION STRUCTURE


Functional locations Structure is a hierarchical Presentation of a Tech.
System.
Gives information about how the Technical System is sub divided into
Individual Functional Units.
Individual function Units are defined on the Basis of Process Orientation,
Functions, or any other Special criteria.
Each functional location is managed independently in the system, so that
you can :

Manage individual data from a maintenance perspective for the object


Perform individual maintenance tasks for the object
Keep a record of the maintenance tasks performed for the object
Collect and evaluate data over a long period of time for the object

Presentation Title | Confidential | Document ID

| Aug 18, 2015

FUNCTION LOCATION STRUCTURE


Description

Code

Structure Indicator

GIL

Structure Indicator Text

GIL Cement Division

Edit Mask

AAA-AANN-AAX-AAX-XXX-XXXXX

Hierarchy Levels

Example

Hierarchy
Level

Edit Mask

Code

Description

Level 1

AAA

GIL

Grasim Industries Limited

Level 2

AANN

RC01

Raja shree Cement

Level 3

AAX

RC1

Raja shree Cement Unit-I

Level 4

AAX

CM1

RC1 Cement Mill-1

Level 5

XXX

FEG

RC1 Cement Mill -1 Feeding


Group

Level 6

XXXX
Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

CONTENTS OF FUNCTIONAL
LOCATION MASTER

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Function Location Structure


Function Location Category
Plant

| Aug 18, 2015

FUNCTION LOCATION CATEGORY


Category

Description

Colony Functional Locations

General Functional Locations

Hierarchical

Plant & Machinery F Locations

Mines Functional Locations

Office Functional Locations

Power Generation F. Locations

Utility Functional Locations

10

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN

Display of Function Location-[IL03]


List Editing of Function Location-[IH06]
Display ( Multi Level) Function Location[IL07]
DISPLAY CONTENTS:
Display Action Log
Object Information

11

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

12

BASIC CONTENTS OF MAINTENANCE


OF EQPT MASTER

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Equipment Category
Plant
Functional Location
Main Planner Group
Tech. Object Type
Plant Section
Main Work Center
Cost Center /Internal Order
Company Code
Class
Warranty data

EQUIPMENT CATEGORY

Defining Equipment Categories is a facility in SAP/PM to


group the vast variety of Equipments that any manufacturing
Organization can have in their Plant. One of the methods of
grouping similar Equipments is to differentiate them on the
basis of their Use and / or the Function that they perform e.g.,
Electrical Equipment. In GIL, this is the basis of defining
Equipment Category shown in the next two slides

13

Presentation Title | Confidential | Document ID

| Aug 18, 2015

EQUIPMENT CATEGORY
CATEGO
RY

14

EQUIPMENT

EXAMPLES

AUTOMOBILE

CARS/JEEP/MOBILE VAN

CIVIL OBJECTS

BUILDINGS/CIVIL EQUIPMENTS

DUMMY EQUIPMENTS

USED IN SYSTEM ONLY FOR RUN HOUR


TRANSFER. NOT TO BE USED

ELECTRICAL EQUIPMENTS

MOTORS/TRANSFORMERS/SWITCH
GEARS

INSTRUMENT EQUIPMENTS

RTDS/PROXIMITY SWITCHES/FIELD
INSTRUMENTS/PANELS

MECHANICAL EQUIPMENTS

GEAR BOXES/DPC/DBC/BELT
CONVEYORS

MINES EQUIPMENTS

SHOVELS/DUMPERS/DRILLING
MACHINES

Presentation Title | Confidential | Document ID

| Aug 18, 2015

EQUIPMENT CATEGORY
CATEGOR
Y

EQUIPMENT

EXAMPLES

PROCESS EQUIPMENTS

CYCLONES/HOPPERS

QC TEST EQUIPMENTS

CUBE TESTING MACHINE /


COMPRESSIVE STR MACHINE

PRODUCTION RESOURCES/TOOLS

CRANES

TPP/DG EQUIPMENTS

TURBINE/ECONOMISER/BOILER

UTILITY EQUIPMENTS

COMPRESSOR/WATER PUMPS

NOTE:
ONLY SPECIFIC TPP/DG EQUIPMENTS OF MECHANICAL/ELECTRICAL CATEGORY WILL GO TO
TPP MECH/TPP ELEC CATEGORY. EQUIPMENTS LIKE MOTORS/ GEAR BOXES/BELT
CONVEYORS WILL GO TO MECHANICAL/ELECTRICAL CATEGORY ONLY.

15

Presentation Title | Confidential | Document ID

| Aug 18, 2015

EQUIPMENTS CATEGORY & NUMBER RANGE

Category

Number
Range
To

Mechanical Equipments

10000000

19999999

Electrical Equipments

20000000

29999999

Instrumentation Equipments

30000000

39999999

Process Equipments

40000000

49999999

TPP & DG Equipments

50000000

59999999

Mines Equipments

60000000

69999999

70000000

79999999

16

Description

Number range
From

Automobiles Equipments

Civil Objects & General Equipt.

80000000

89999999

Safety Equipments

90000000

99999999

QC Test Equipments

1000000

1999999

Presentation Title | Confidential | Document ID

| Aug 18, 2015

TECHNICAL OBJECT TYPE

Technical Object Types are the logical grouping of Objects on the


basis of similarity of function being performed by each one.
Examples :

17

ME_GEARBOX

Gear Box

EL_MOTORS

Electrical Motors

ME_FANS

Fans

Presentation Title | Confidential | Document ID

| Aug 18, 2015

PLANNING PLANT

Plant in which maintenance tasks are planned and executed. In GIL ,


Planning Plant is also a Maintenance Plant. Different Planning Plants in GIL
are :
Aditya Cement
Grasim Cement
Vikram Cement
Rajashree Cement
Grasim South
Birla Super Cement (Hotgi)
Birla Plus Cement (Bhatinda)

18

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAIN WORK CENTER


Main Work Center is Logical Grouping of all Work Centers, which are
Performing similar nature of Maintenance Tasks/Activities in different
Plant Sections. E.G. Mechanical Main Work Center is a Group of Plant
Maintenance Persons, who are executing Mechanical Maintenance
activities . Different Main Work Centers defined are :
Mechanical Department
Electrical Department.
Instrumentation Department.
Process Department.
Civil Department, Etc.

19

Presentation Title | Confidential | Document ID

| Aug 18, 2015

PLANT SECTION
Plant Section is a division of Maintenance Plants into Production
Areas.

Plant
GC01
GC01
GC01
GC01
GC01

20

Category

Description

RM1

Raw Mill -1

CO1

Coal Mill -1

KL1

Kiln -1

CM1

Cement Mill -1

PP1

Packing Plant -1

Presentation Title | Confidential | Document ID

| Aug 18, 2015

PLANNER GROUP

Planner Group defines the Group of People (Employees) responsible


for Planning and Execution of Maintenance Activities in a Particular
Plant.
PLANNER GROUP CODIFICATION LOGIC

21

PLANNER GROUP =

MAIN WORK CENTER + PLANT SECTION

MCM
ECM
ICM

Mechanical
Electrical
Instrumentation

=
=
=

Presentation Title | Confidential | Document ID

| Aug 18, 2015

+
+
+

Cement Mill
Cement Mill
Cement Mill

COST CENTER/ INTERNAL ORDERS


Cost Centers are logical Organizational Units where the costs are
incurred for value addition . Costs incurred are ultimately settled to Cost
Centers through Orders.
Internal order is nothing but an intermediate cost collector between PM
order and cost center. Internal Order will be used in Mines Equipment
only.
Cost Center Concept as applied in GIL :
Plant Section
= Superior Cost Center
Department
= Sub Cost Center in that Plant section
CEMENT MILL

Mechanical

22

Electrical

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Instrumentation

Process

NAVIGATE > SAP SCREEN

Creation of Equipment-[IE01]
Change of Equipment-[IE02]
Display of Equipment-[IE03]
List Editing of Equipment-[IH08]
Display ( Multi Level)-[IE07]
DISPLAY CONTENTS:
Display of Usage List
Display Action Log
Display Object Information
Installation & Dismantle

23

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

24

BASIC CONTENTS OF CLASS &


CHARACTERISTICS MASTERS

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Class Type
Class Group
Characteristics Group
Unit of Measure for
Characteristics Master

| Aug 18, 2015

CLASS

Classes are :

25

Logical Grouping of Equipments having Similar Functions.


Class Mainly Depends on the Main Function / Activity being
Performed by that Equipment.
It helps to know the Number of Equipments having the same
Class.
Class data will never Change throughout the entire Productive
Life-Cycle of the Equipment.
This information can be used for Proper Planning of Spares,
for planned Maintenance & obtaining the History of that Class
of Equipments.

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CHARACTERISTICS

Characteristics are the Specifications or Designed Parameters of


Measurement for the Equipments. Ex. Flow of Fan , Gear Ratio of Gear
Box.
Combination of Class and Characteristics helps in Precise search of
Equipments.
For Example:

26

Select Gearbox of Particular Make / Ratio.


Select Class as Gearbox & Characteristics as Make/ Ratio. Enter
Relevant Values of these Characteristics.
System will search & display all Gearboxes satisfying above
Characteristics Values

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CLASS

Electrical

Mechanical
Class

Description

Class

Description

GEARBOX

GEARBOX

LTMOTOR

LT MOTOR

BUCKETELELVATOR

BUCKET ELELVATOR

LTFEEDER

LT FEEDER

BALLMILL

BALL MILL

BATTERY

BATTERY

BAGHOUSE

BAG HOUSE

BREAKER

BREAKER

27

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CLASS AND CHARACTERISTICS GROUPS CODES

Char. Group Code Description


PM_EQ_ELEC

PM Elec. Equipments Specs.Char. Group

PM_EQ_GENL

PM General Equip. Specs. Class Group

PM_EQ_INST

PM Inst. Equipments Specs.Char. Group

PM_EQ_MECH

PM Mech. Equipments Specs.Char. Group

PM_EQ_MINE

PM Mine. Equipments Specs.Char. Group

PM_EQ_PROC

PM Proc. Equipments Specs.Char. Group

PM_EQ_SAFE

PM Safety Equip. Specs. Char Group

PM_EQ_TPDG

PM TPP & DG Equip. Specs. Char. Group

28

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN

Display of Class List [CL03]


Find Object in Class- [CL30N ]

29

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

30

BASIC CONTENTS OF MICs MASTER

Plant

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Range of Characteristics Value

| Aug 18, 2015

MASTER INSPECTION CHARACTERISTCS


Specific parameters of an Equipment for Calibration
Parameters to measure whether Equipment is performing its function
The Parameter driving / governing Equipment performance/Output is
within acceptable limits.
Example: Mili-amperes / Mili-volts for weigh Feeder

31

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN

Find out The Maintenance Inspection Characteristics prepared-[QS24]

32

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.

BASIC CONTENTS OF WORK CENTER


MASTER

Functional Locations
Equipment Master
Class & characteristics
MICs

Plant
Work Center Category
Control Key
Cost Center

5. Work Center

6.
7.
8.
9.

33

Work Dimension - Time

Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Work Unit

| Aug 18, 2015

WORK CENTER
Work Center is a Person/Group of Persons, who perform Maintenance Activities.
Work Center Category
Each Department will have two categories, Permanent and Contractor.
Category

Description

0021
0022

Mechanical Permanent
Mechanical Contractor

Example : M1F1W3K, MC1F1W3K etc.


Codification Logic :
M1F1W3K
MC1F1W3K

34

= Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi


= Mech. Contractor / 1 Fitter /1Welder / 3 Khalasi

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN

Work Center List-[IR03]


DISPLAY CONTENTS:
Relevant Number for Permanent and Contractor Work centers
for your department.
Different combinations of Skills.

35

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

36

BASIC CONTENTS OF MEASURING


POINT MASTER

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Equipment Master
Function Location Master
Category of Measuring Point
Characteristics
Unit of Measures

| Aug 18, 2015

MEASURING POINT
It is a Measurement characteristic/Parameter attached to an Equipment
Describe the Physical and/or Logical Locations of Equipment
at which a Condition / Parameter is to be measured.
Measuring Point will be always for an Equipment or FL or assembly
but Generally for Equipments.
Measurement readings are taken for an Equipment at regular
interval to know the Condition at that time.

37

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MEASURING POINT

Continued..

Measuring Point is also Used as Counter where values Measured


by a Measuring Point can be summed up during a time period for
monitoring and control .
Example:
Running hours of Any Equipment
Lubrication Consumption.

38

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN(MP)

Creation Of Measuring point [IK01 ]

Change / Display Of Measuring Point [IK02/ IK03]


Display List Editing-[IK07]
Create Entry List-[IK31]
Collective entry of measuring document-[IK34]

DISPLAY CONTENTS:
Transfer of Measuring point

39

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

40

BASIC CONTENTS OF TASK


LIST MASTERS

Function Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Group Coding
Counter
Planning Plant
Maintenance Strategy
Work Center
Set of Operations
MIs

| Aug 18, 2015

TASK LIST

A Set of Activities to be Performed on an Equipment or Functional


Location.
Three types of Task Lists :
Functional Location Task List[T]
Equipment Task List[E]
General Task List[A]

41

Presentation Title | Confidential | Document ID

| Aug 18, 2015

TASK LIST CODIFICATION


seq
1

Codification Logic for defining Task List Group - It has to be Planning Plant / Maintenance Specific

XX

GIL Plant Short Code:

RC = RC01, GS = GS01, GS = GS01, GC = GC01, BS = BS01.


Discipline:

XX

E = Electrical, M = Mechanical, I =Instrumentation, P = Process, N = Mines, T = TPP,


= QC,S = Safety
Equipment Short "Equipment Class Code":

GB = Gear Box, BF= Bag Filter, BC = Belt Conveyor,


Equipment Class Code Type( application) :

XX

GB Gear Box Helical; Radial; BE-Bucket Elevator Belt/ Chain


Type of Maintenance Task List:

Example:

42

AT = Analyzer, MO= DC Motor, etc

PM=Preventive Maintenance , AM = AMC Tasks, CA= Calibration ; SD = Shutdown ,


IN
= Inspection (attribute/Value EN-Environment;) J-Jishu Hozen ( General Inspection ) ZXSafety
GCMGBHPM

GCM-GBH-PM 1M Checks

GCEMODPM

GCE-Motor-DC-PM 3M Checks

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE STRATEGY

Set of Predefined Prefixed Time Intervals ( Called Packages) grouped


at Which Preventive Maintenance Activities can be taken Up.
These Maintenance Strategies can be selected By User to carry out
Maintenance Activities depending Upon :-

43

Age of Equipment
Design of Equipment
Importance of Equipment in Production Process
Maintenance Practices of Organization.

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE STRATEGIES

GILDAY -- Frequencies Specified in GILDAY

Are 1W / 2W / 1M / 3M / 6M / 1Y
GILMON-- Frequencies Specified in GILMON
Are 6M/ 1Y/ 2Y/ 5Y
MINEHR -- Frequencies Specified in MINEHR
Are 100HR/ 300HR / 350HR/ 400HR
PERFHR -- Frequencies Specified in PERFHR
Are150HR / 250HR / 500HR/ 1000H

44

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Continued..

APPLICATION:

Continued..

GILDAY: Strategy is Used for Frequencies of Check Up to 6M.

GILMON: Strategy is Used for Frequencies of Checks More than 6M.


MINEHR: Strategy is Used For MINES Preventive Maintenance Planning.
PERFHR: Strategy is Used For PLANT/TPP/DG Preventive Maintenance
Planning.

45

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE PACKAGE
Strategy GILDAY

Cycle Length

UOM

Maintenance Cycle Text

Cycle Short Text

DAY

Weekly (1 Week )

1W

14

DAY

Fortnightly (2 Weeks )

2W

28

DAY

Monthly ( 4 Weeks )

1M

84

DAY

Quarterly ( 12 Weeks )

3M

168

DAY

Half yearly ( 24 Weeks )

6M

336

DAY

Yearly ( 48 Weeks )

1Y

Cycle Length

UOM

Maintenance Cycle Text

Cycle Short Text

MON

Half yearly

6M

12

MON

Yearly

1Y

24

MON

2 Yearly

2Y

48

MON

5 Yearly

5Y

Strategy GILMON

46

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE PACKAGE

Continued..

Strategy MINEHR

Cycle Length

UOM

Maintenance Cycle Text

Cycle Short Text

96

HR

100 Running Hours ( 96 Hrs)

P1

312

HR

300 Running Hours ( 312 Hrs)

P2

360

HR

350 Running Hours ( 360 Hrs)

P3

408

HR

400 Running Hours ( 408 Hrs)

P4

504

HR

500 Running Hours ( 504Hrs)

P5

1008

HR

1000 Running Hours (1008 Hrs)

P6

1512

HR

1500 Running Hours (1512 Hrs)

P7

2016

HR

2000 Running Hours (2016 Hrs)

P8

2496

HR

2500 Running Hours ( 2496 Hrs)

P9

3000

HR

3000 Running Hours ( 3000 Hrs)

1P

47

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE PACKAGE

Continued..

Strategy PERFHR

48

Cycle Length

UOM

Maintenance Cycle Text

Cycle Short Text

144

HR

150 Running Hours ( 144 Hrs.)

P1

240

HR

250 Running Hours ( 240 Hrs.)

P2

504

HR

500 Running Hours ( 504 Hrs.)

P3

1008

HR

1000 Running Hours (1008 Hrs)

P4

2496

HR

2500 Running Hours (2500 Hrs)

P5

4032

HR

4000 Running Hours (4032 Hrs)

P6

8064

HR

8000 Running Hours (8064 Hrs)

P7

12096

HR

12000 Running Hours (12096 H)

P8

16128

HR

16000 Running Hours ( 16128 H

P9

24192

HR

24000 Running Hours ( 24192 H

1P

32256

HR

32000 Running Hours ( 32256 H

2P

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN

Display Task List-[IA07]

List Editing Task List-[IA09]


DISPLAY CONTENT:
Find Task Lists in your Planner group.

49

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

50

BASIC CONTENTS OF MAINTENANCE


ITEM MASTER

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Equipment /Function Location


Master
Task list Master
Strategy

| Aug 18, 2015

MAINTENANCE ITEM

Maintenance Item describe Preventive Maintenance Tasks


to be performed on an Equipment at Predefined Interval
Maintenance Item = Equipment + Task List with set of operations
with Maintenance Package

51

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE MASTERS
BASIC MASTERS

1.
2.
3.
4.
5.
6.
7.
8.
9.

52

BASIC CONTENTS OF MAINTENANCE


PLAN MASTER

Functional Locations
Equipment Master
Class & characteristics
MICs
Work Center
Measuring Point
Task List Master
Maintenance Item
Maintenance Plan

Presentation Title | Confidential | Document ID

Maintenance Item Master


Strategy
Scheduling parameter

| Aug 18, 2015

MAINTENANCE PLAN

Maintenance Plan is the Scheduling of Task List attached to an


Equipment (Maintenance Item ) on Time Scale ( According to
Factory Calendar ) or Performance scale ( According to Counter
i.e. Number of Hours).

Plan = Maintenance Item + Scheduling Parameters

53

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE SCHEDULING PARAMETER


TOLERENCE: ( 50% )
It is the difference between planned date and TECO date ,given in %age for
deciding whether maintenance cycle should be shifted or not, considering
the gap between planned date and TECO date.
Shift factor will be effective only if difference between planned date and
TECO date is more than 50% of smallest interval (smallest package) , either
+ or side. If difference between planned date and TECO date is less than
50% of smallest interval (smallest package) , there will be no shift. For
GILDAY , it will be + / - 3.5 days , as minimum frequency is 1w. For GILMON
it will be +/- 3 months as min freq is 6M.
SHIFT: 100% .
If condition given in Tolerance is true it will shift the maintenance cycle
by : given shift % x difference between planned date and TECO date .i.e.
Actual delay

54

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE SCHEDULING PARAMETER

Continued..

CALL HORIZON 50%


It indicates that an advance intimation of planned maintenance will be
given by 0.5 x minimum frequency of strategy selected through order
generation .
FOR GILDAY :
1W Being minimum frequency , you will get weekly order 3.5 days
in advance if call horizon is 50%.

55

Presentation Title | Confidential | Document ID

| Aug 18, 2015

II. MANAGING MAINTENANCE PROCESSES

56

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE PROCESSES
BASIC PROCESSES

BASIC STEPS OF MAINTENANCE


PROCESSES

1.
2.
3.
4.
5.
6.
7.

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

57

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Creation of Notification
Creation of Orders
Execution of Orders
Confirmation of Orders
Technical Confirmation of
Orders
Creation of Purchase Request
Creation of Purchase Orders
Service Entry Sheets
Creation of Measuring Points
& Measuring Documents
Installation / De-installation of
Equipments

1. PREVENTIVE MAINTENANCE PROCESS


BASIC PROCESSES

1.
2.
3.
4.
5.
6.
7.

58

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

Presentation Title | Confidential | Document ID

BASIC STEPS OF PREVENTIVE


MAINTENANCE PROCESS

Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of

| Aug 18, 2015

Orders

1. PREVENTIVE MAINTENANCE PROCESS


Selection of Order

BASIC STEPS OF MAINTENANCE


PROCESSES

Go to T. Code - IW39

Selection of Orders

Execution of Orders

Flag Outstanding & In process


check box

Confirmation of Orders

Technical Completion of Orders

Enter Order Type PM01

H/L TO ORDER TYPES

Select from Drill Down

Enter Period ( Date from..to


)
Enter Status exclusive in
Multiple Selection

CRTD, CNF ,
TECO & CLSD

Enter Maintenance Plant


Enter Planner group for Order
Execute by clicking
button
Order list of relevant section
Appears
59

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

ORDER TYPES
PM01 --- PREVENTIVE MAINTENANCE ORDERS

These Orders are Planned by SAP System

User can not generate PM Work Order for this Order Type externally.

This Order type will help User to find out Cost of Preventive Maintenance
exclusively for his Plant section/Planner group.

User will be able to compare Cost Of Preventive Maintenance vis--vis


Breakdown and Shutdown Maintenance.

User will be able to judge the effectiveness of Preventive Maintenance Plans by


this Order Type.
Order Numbering is blocked for this Order

60

User will get Preventive Maintenance Orders under Maintenance Activity Type PVM , Annual Maintenance Contract Orders under Maintenance Activity Type AMC and Inspection Orders under Maintenance Activity Type INW

Presentation Title | Confidential | Document ID

| Aug 18, 2015

ORDER TYPES

Continued..

PM02: BREAKDOWN MAINTENANCE ORDERS


This Order Type is exclusively for Breakdown registration of Equipments
This Order Type indicates Unplanned stoppage in Production Process
In addition to consumption of Recourses like Men , Machine , Material ,
Production loss is also associated with this type of Order .
User can further segregate the breakdowns of Equipments under Warranty /
Insurance from other Breakdowns.
PM03: SHUTDOWN MAINTENANCE ORDERS
This Order Type indicates
Annual Shutdowns ( Maintenance Activity Type: SDM)
Planned Weekly,Fortnightly,Monthly Stoppages ( Maintenance Act. Type : WFM)
Opportunity Based Maintenance (Maintenance Activity Type: OPP)
The Annual Shutdowns as per Purta /Budget and approved as Shutdowns by Management will be
booked under MAT- SDM.

61

Presentation Title | Confidential | Document ID

| Aug 18, 2015

ORDER TYPES

Continued..

PM03: SHUTDOWN MAINTENANCE ORDERS


Only Planned Weekly,Fortnightly,Monthly Stoppages will be booked under Maintenance
Activity Type WFM
Other Maintenance jobs not planned but undertaken because of availability of Opportunity are
booked under MAT-OPP.
PM05: CALIBRATION MAINTENANCE ORDERS
This Order Type is applicable for Calibration of Equipments
These Orders are Planned by System . However , User can also raise Order externally , if
required for unplanned Calibration jobs.
This Order Type has MAT- CAL .
PM06 : CORRECTIVE MAINTENANCE ORDERS
The jobs covered under this Order Type are of 2 types:
Corrective Actions suggested under WHY-WHY Analysis to avoid recurrence of Breakdown will
be covered under Maintenance Type WHY .

62

Presentation Title | Confidential | Document ID

| Aug 18, 2015

ORDER TYPES

Continued..

PM06 : CORRECTIVE MAINTENANCE ORDERS


Other Maintenance Jobs of Corrective Nature e.g. Maintenance Requests from other
departments , Removal of Abnormalities/Defects, Removal of Unsafe Conditions where
Breakdown has not occurred will be covered under MAT- CRM
PM07 --- CONDITION BASED MAINTENANCE ORDERS
This Order Type is applicable for jobs planned on the basis of Condition of Spares. E.g.
Replacement of Worn Out Chain/ Worn-out Hammers etc
MID , being Condition Monitoring Department , will use this Order Type for advising repair /
replacements on the basis of Condition E.g. Hardness/Thickness/Vibrations etc
PM08 --- GENERAL MAINTENANCE ORDERS
This Order Type is applicable for UNDEFINED jobs NOT FALLING under above categories
and not related to Equipment. E.g. Leakage of Water Tap in Administration Building garden.
These are of Minor nature Repair Jobs.
This Order Type should not be used unless it satisfies above condition

63

Presentation Title | Confidential | Document ID

| Aug 18, 2015

ORDER TYPES

Continued..

PM09: REPAIR MAINTENANCE ORDERS


There are Four different Activity Types or jobs covered under this category. They are:
Work Shop jobs should be registered under MAT RWS
Rewinding jobs should be registered under MAT - REW
Tyre Retreading jobs should be registered under MAT RET
External Repair jobs should be registered under MAT RVN
PM10: IMPROVEMENT/MODIFICATION ORDERS
All jobs of Improvements and Modifications in Maintenance (Reliability
MTTR/MTBF/Maintainability/Availability) are covered under Maintenance Activity Type IMO
Suggestions given by Consultants/Experts/Other Units/ Other sources like
Websites, Manuals, Magazines etc are covered under Maintenance Activity Type CON.
PM11: CAPEX/BLOCK ORDERS
All Work Orders raised for Project Work are covered under this Order Type and MATCAP
PM12 --- CIVIL MAINTENANCE ORDERS

64

All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/
Foundation
Presentation
Title | Confidential
Document
ID | Aug
18, 2015
etc are
covered
under| this
Order
Type
and MAT-CIV

MAINTENANCE ACTIVITY TYPES IN PM ORDERS

65

Order Type

Description

Order Activity Type

PM01

Preventive Maintenance Order

PVM,AMC,INW

PM02

Breakdown Maintenance Order

BDM,WAR,INS

PM03

Shutdown Maintenance Order

SDM,OPP,WFM

PM05

Calibration Order

CAL

PM06

Corrective Maintenance Order

CRM,WHY

PM07

Condition Based Maintenance

CBM

PM08

General Maint Order

GEN

PM09

Repairs Order

RWS,RVN,RET,REW

PM10

Improvement/Modification Order

IMO.CON

PM11

Capex / Block order

CAP

PM12

Civil Maintenance Order

CIV

QCAL

QC Insp./ Calibration Order

CAL

Presentation Title | Confidential | Document ID

| Aug 18, 2015

1. PREVENTIVE MAINTENANCE PROCESS


Selection of Order

BASIC STEPS OF MAINTENANCE


PROCESSES

Go to T. Code - IW39

Selection of Orders

Execution of Orders

Flag Outstanding & In process


check box

Confirmation of Orders

Technical Completion of Orders

Enter Order Type PM01

H/L TO ORDER TYPES

Select from Drill Down

Enter Period ( Date from..to


)
Enter Status exclusive in
Multiple Selection

CRTD, CNF ,
TECO & CLSD

Enter Maintenance Plant


Enter Planner group for Order
Execute by clicking
button
Order list of relevant section
Appears
66

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

1. PREVENTIVE MAINTENANCE PROCESS


BASIC STEPS OF MAINTENANCE
PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

67

Presentation Title | Confidential | Document ID

Select desired order


Move to SAP Screen

| Aug 18, 2015

1. PREVENTIVE MAINTENANCE PROCESS


Execution of Orders

BASIC STEPS OF MAINTENANCE


PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Go to T. Code - IW32
Enter number of Selected Order
Release PM01 Type Selected
Order
Go to Operation TAB and
Change operations etc if reqd
Select operation & Go to
Component TAB if Material
Required
Select required Component
Enter reqd Qty , Item category,
Storage Location & Batch
Come to Header data Tab
Enter Start Date & Time

68

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Order status will be


changed to REL from
CRTD

1. PREVENTIVE MAINTENANCE PROCESS


BASIC STEPS OF MAINTENANCE
PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

69

Presentation Title | Confidential | Document ID

Schedule Order by Clicking


Determine cost by clicking
Save the Order
Move to SAP Screen

| Aug 18, 2015

End date & time will


be changed by system

1. PREVENTIVE MAINTENANCE PROCESS


Confirmation of Order

BASIC STEPS OF MAINTENANCE


PROCESSES

Selection of Orders

Execution of Orders

Confirmation of Orders

Technical Completion of Orders

Go to T. Code IW44
Select Header Menu
Confirmation
Select via operation list in
Confirmation Menu
Selection of operation list
appears
Enter Plant
Enter Order type

Select from Drill Down

Enter Reference date


Enter Planner group
Enter Status Exclusive in Multi
Selection List
70

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CRTD, CNF ,
TECO & CLSD

1. PREVENTIVE MAINTENANCE PROCESS


Execute by clicking button

BASIC STEPS OF MAINTENANCE


PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

All relevant Orders with


Operations will be copied on
main screen
Select All Operations
Click All Actual Data on Header
Tool bar
All Planning data of operations
defaulted from relevant Orders
Enter Actual Work Center Qty
Flag Final confirmation, Clear
all Res & No remaining work
Enter Start Date & Time
Enter End Date & Time

71

Presentation Title | Confidential | Document ID

| Aug 18, 2015

1. PREVENTIVE MAINTENANCE PROCESS


Enter Actual Duration

BASIC STEPS OF MAINTENANCE


PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Enter Confirmation Text


System will calculate Actual
Duration
Save Confirmation by clicking
Move to SAP Screen

72

Presentation Title | Confidential | Document ID

| Aug 18, 2015

1. PREVENTIVE MAINTENANCE PROCESS


BASIC STEPS OF MAINTENANCE
PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

Technical Completion of
Order
Go to T. Code - IW32
Selection of Order Screen
appeared
Flag In process check box
Enter Order Type PM01
Enter Period (Date fromto)
Enter Status exclusive in
Multiple Selection

CRTD, REL ,
TECO & CLSD

Enter Maintenance Plant


Enter Planner group for Order
Execute by clicking
button

73

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

1. PREVENTIVE MAINTENANCE PROCESS


BASIC STEPS OF MAINTENANCE
PROCESSES
Selection of Orders
Execution of Orders
Confirmation of Orders
Technical Confirmation of
Orders

Order list of relevant section


Appears
Select order and click
Order Main Header Screen
Opens
Click Settlement Rule button
Enter / change cost center &
give % if required
Click Flag of Technical
Completion
Enter Reference Date & Time
Click Enter

Button

Order is Technically Completed


& System Status Changed to
TECO
Move to SAP Screen
74

Presentation Title | Confidential | Document ID

| Aug 18, 2015

2. BREAKDOWN MAINTENANCE PROCESS


BASIC PROCESSES

1.
2.
3.
4.
5.
6.
7.

75

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

Presentation Title | Confidential | Document ID

BASIC STEPS OF BREAKDOWN


MAINTENANCE PROCESS
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

| Aug 18, 2015

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Creation of M2 Notification
Go to T. Code IW21Create
Notification
Enter Notification Type
Do not Enter Notification
Number
Notification Tab Screen Appears
Click Enter Button
Enter Notification Description

Enter Reported By (Name)

Presentation Title | Confidential | Document ID

Select from Drill Down


H/L TO N/F Types

Enter Equipment / FL /
Assembly (as required)

76

Manual Process

| Aug 18, 2015

System Generated

NOTIFICATION TYPES

Continued..

M1 --- MAINTENANCE REQUEST

This Notification type indicates a request made by Customer department to his


Supplier/Service Provider. E.g Request made by Raw Mill Mechanical for repair of
Gear Box shaft on Workshop.
This includes all types of jobs of Maintenance/Repair/Service requests made by User
on Service Provider EXCEPT Malfunction/Breakdown.
M2 --- MALFUNCTION/BREAKDOWN

This Notification Type is exclusively for information regarding Breakdown of


Equipments
This Notification is raised generally by Production on relevant Maintenance
Department as a FIR of Unplanned stoppage in Production Process.
However , anybody can raise this Notification if it satisfies above condition.

77

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NOTIFICATION TYPES

Continued..

M3 --- UNSAFE CONDITION/ACCIDENT


This Notification is an information from any department including Safety
regarding prevailing Unsafe/ Hazardous Condition which is dangerous and may
cause damage to Property/Human being / Environment /Surroundings etc , to
the relevant department responsible for such condition for necessary corrective
action.
M4 --- ABNORMALITY RECORD
This notification is raised to register 7 types of Basic Defects in Equipments.
These defects are revealed through Daily Check List/ Inspection/Plant Round
Satisfies the WCM requirement to monitor 7 type of basic defects which are
responsible for Breakdown , if not corrected in time.

78

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NOTIFICATION TYPES

Continued..

M5: RECOMMENDATION/IMPROVEMENT
This Notification is generated by User for any improvement/development to be
implemented .
The source for Improvement/Modification/Development in Reliability/ Availability
/Maintainability may be WHY-WHY Analysis, Experts/Consultants
recommendation/Other Units/KIPs etc
The number of such Notifications will be an indicator of improvements done by
User
These notifications will give List of Improvements done by User which is required
by WCM or for sharing with other Units.
M6 --- WORK REQUEST-WORKSHOP
This notification is raised by User on workshop requesting its services for
Repair/Machining/Replacement of Spares/Assembly/Equipment etc.

79

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NOTIFICATION TYPES

Continued..

M7: GENERAL NOTIFICATION.


Notification which does not fall in any of the conditions mentioned above may be
raised in this type.
This type of Notification should not be used as far as possible as it will affect
history/vital information about Equipments.
M8: MEASURING POINT ERROR
This notification is raised by the SAP system automatically whenever the
Parameter defined as a Measuring Point deviates from its Standard Value or goes
beyond its Acceptable Permissible Value.

80

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Notification Types

Notification Type
M1
M2
M3
M4
M5
M6

81

Description
Maintenance Request
Malfunction, B/Down
UnsafeCond./Accident
Abnormality Record
Recommendation
Work Request- W.Shop

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Number Ranges From -To


1000000000 to 1999999999
2000000000 to 2999999999
3000000000 to 3999999999
4000000000 to 4999999999
5000000000 to 5999999999
6000000000 to 6999999999

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Creation of M2 Notification
Go to T. Code IW21Create
Notification
Enter Notification Type
Do not Enter Notification
Number
Notification Tab Screen Appears
Click Enter Button
Enter Notification Description

Enter Reported By (Name)

Presentation Title | Confidential | Document ID

Select from Drill Down


H/L TO N/F Types

Enter Equipment / FL /
Assembly (as required)

82

Manual Process

| Aug 18, 2015

System Generated

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Popup Massage of warranty


Prompts
Enter Code of STD TEXT
Attached
Main Work center/ Planner
Group etc Defaulted & can be
Changed If Required
If Reqd Enter Long Text
Go To Location Data Tab
Flag breakdown check box
Release & Save the Notification
In case of Main Plant, M2 Type
Notifications will be Generated
by System thru breakdown entry
made by CCR
Naviaget >SAP Screen

83

Presentation Title | Confidential | Document ID

If equipment Under
warranty

| Aug 18, 2015

All information Defaulted


from equipment master

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Selection of M2 Notification
Go to T. Code IW28 Selection
of Notification
Flag check box Outstanding or
In process (as Reqd)
Enter Notification Date
Enter Planner group
Select from Drill Down

Enter Maintenance Plant


Click Enter Button
List of Notifications Appears as
per Selection Criteria
Select relevant Notification
Click on Details Button
Notification Change Screen
Appears

84

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Navigate. SAP Screen

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Creation of PM02 Type Order


from Notification
M2 Notification selected in
Changed Mode as explained in
pervious sheet
Click Create button
of Order Tab
Create Order Popup Screen
Appears with Defaulted data
from notification
Enter PMActType BDM & click
continue button & save
Breakdown Order Created
Further process of order will
remain same as explained in
process 1. Preventive
Maintenance
Navigate> SAP Screen

85

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

86

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Process of Selection of Order,


Execution of Order, confirmation
& TECO will be similar to processes
explained in process
1. Preventive Maintenance

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Execution of M2 Notification
(Order not generated)
M2 Notification selected in
Changed Mode as explained in
pervious Process
To Attach Std Text Go to Effect
field & select relevant code of
Std Text
Insert Text popup screen
appears.
On Insert Text screen Flag
Expand immediately , enter Text
ID ST & click on dropdown of
Text Name field
Next Popup screen Database
selection for SAP script text
Execute Popup screen
Database selection for SAP
script text without entering any
data

87

Presentation Title | Confidential | Document ID

Select from Drill Down

| Aug 18, 2015

Select from Drill Down

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Next Popup screen Find SAP


script text will appear. Select
relevant text & click continue
button
Now popup screen Insert Text
appear again with text attached.
Click Continue Button
Desired Standard Text Get
copied in long text. Complete it
& go back to main screen
Select malfunction& downtime
tab and Enter down time end
Date &Time.
Click Complete Flag and
complete Notification
Navigate> SAP Screen

88

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Create Why Why Analysis


Sheet
Go to T. Code -- ZRPM-WHY
Enter Plant , Plant Section &
Planner group
Enter Date Range (From...To)
Select status by flagging and
execute
List of Notification appears (as
per selection criteria)
Select relevant notification &
double click it
Why Why Analysis screen
Appears

89

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Enter Object Code

Select from Drill Down

Enter Damage Code

Select from Drill Down

Enter all Possible Causes


(Possible reasons)

Select from Drill Down

Flag YES box to actual Cause


Enter Observations
Enter Analysis In Why Why
Field
Enter Rectification carried out
Enter Recommendations
Enter Responsible person and
Tar Date for Recommendations
Select Document Attached Say 2

90

Presentation Title | Confidential | Document ID

| Aug 18, 2015

2. BREAKDOWN MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

Next procedure of Standard text


shall be similar as explained in
Process Execution of M2
Notification
Click Complete Flag and
Complete Notification
Save why-why Analysis
Change Why Why Analysis
Go to T. Code ZRPM_WHY
Go to Main screen of selected
Notifications why why analysis
Click Put in Process Flag
Change Why Why analysis data
as per requirement

Navigate> SAP Screen


91

Presentation Title | Confidential | Document ID

Save changed why-why


Analysis
| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC PROCESSES

1.
2.
3.
4.
5.
6.
7.

92

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

Presentation Title | Confidential | Document ID

BASIC STEPS OF SHUTDOWN


MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 - Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 - Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Report of Shutdown Planning
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Creation of Shutdown Order


Go to T. Code IW31
Enter Order Type - PM03

Select from Drill Down

Enter Equipment Number

By Drill Down go to
selection screen

Equipment selection screen


appears
Enter Equipment Class (Optional)

Select from Drill Down

Equipment Category - M

Select from Drill Down

Maintenance Plant

Select from Drill Down

Enter plant Section

Select from Drill Down

Enter Planner Group

Select from Drill Down

Click Execute Button

93

Presentation Title | Confidential | Document ID

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 - Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Select Desired Equipment &


click . Equipment entered in
field
Enter Planning Plant & Enter
Create Shutdown
Maintenance Order : Central
Header Screen appears
Enter Order Description
Go to Header data Tab & Enter
PMActTYPE - SDM
Go to Operation Tab and Enter
Operations as required
Enter Relevant Work Center
Enter Relevant Control key
Better to Create Separate Order
for PMIN & PMEX Control key
Pl Refer Next Slide

94

Presentation Title | Confidential | Document ID

Select from Drill Down

| Aug 18, 2015

Select from Drill Down

PMIN

After Assigning Control Keys

Enter Work or Duration

Select Operations

Enter WC Qty and Cal.Key

Click on External Button

Activity type Defaulted

Popup screen External


Processing Operation appears

Select Operation & Go to


Component TAB if Material
Required

Select Material Group ( S524


For External Services) & Pur.
Group

Select
from Drill
Down

Enter Vender , tracking No &


click

Select
from Drill
Down

Enter required Material, qty,


S.Loc (see stock) & Batch

Select
from Drill
Down

Again Go to Operation screen


Enhancement Button and
enter Field key ZPM0001,
Position

Select
from Drill
Down

Click Gen Data Button & Get


Reservation Number on comp
detail screen & come back

95

PMEX

Presentation Title | Confidential | Document ID

External Processing operation


Appears
Go to service tab & Select
Desired Services from Service
Master or write Description only
& Enter Required Quantity
Enter Cost Element & Press
Enter

| Aug 18, 2015

Select
from Drill
Down

Enter Cost Element & Press


Enter

Click scheduling & determine


cost button

Create Purchase Requisition


screen appears. Enter Dept and
Press Enter

For Release Order Press Icon


Save Order by click button

Repeat above three steps for


Next Operation's

Navigate> SAP Screen

Go to Header Screen & Click


Determine cost button
You can
See PR No
Thru GEN
data->Act
data Tab

For Release Order Press Icon


Save order by click button
Navigate> SAP Screen

96

Presentation Title | Confidential | Document ID

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 Shutdown Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Report of Shutdown Planning
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

97

Presentation Title | Confidential | Document ID

Process of Selection of
Order, Execution of Order,
confirmation & TECO will be
similar to processes
explained in process
1. Preventive Maintenance

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 - Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

98

Presentation Title | Confidential | Document ID

Report1. of Shutdown
Planning
Go to T. Code IW49N
Display order & Operation:
selection of order & Operation
screen appears
Flag Outstanding & In process
Order
Enter Order type
Enter Main work center

Select from Drill Down


Select from Drill Down

Enter Period (dates)


Maintenance Plant

Select from Drill Down

Enter Plant Section

Select from Drill Down

Enter Planner Group

Select from Drill Down

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 - Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

99

Presentation Title | Confidential | Document ID

Click Execute Button


Report of Order with Operation
etc Appears
View Reports with Relevant
Layout selection
Navigate> SAP Screen

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 -Shutdown
Orders
Selection of PM03 -Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

100

Presentation Title | Confidential | Document ID

Report 2 of Shutdown
Planning (MATERIAL)
Go to IWBK Material
Availability Check (for orders)
Material availability Information
screen
Click Multiple Selection of Order
Field
Click Multiple selection button

Select from Drill Down

Flag outstanding & In process


Enter Order Type- PM09
Enter Period (dates)
Maintenance Plant

Select from Drill Down

Enter Plant Section

Select from Drill Down

Enter Planner Group

Select from Drill Down

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 -Shutdown
Orders
Selection of PM03 -Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Navigate> SAP Screen


101

Presentation Title | Confidential | Document ID

Click Execute Button


Report of Order with Operation
etc Appears
Go to back to Multiple selection
screen & Execute
Paste Selected Orders &
execute
You will reach back to main
screen of Material availability
Information
Click execute button again
Screen of Availability list of
Materials for Operations will
appears
On This Screen You Will Get
Order wise Materials with Stock
Availability status
| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 -Shutdown
Orders
Selection of PM03 -Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order (For Contractors)
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Creation of Direct Purchase


Order (For Contractors)
Go to T. Code ME21N Create
Purchase Order
Select Type of Purchase Order

Select from Drop Down

Enter Vendor Code

Select from Drop Down


thru Vendors : Purchasing

Enter Purchase Organization,


Purchase Group & Company
Code
Go to item overview Tab and
Enter Account Assignment K
and Item category - D

Presentation Title | Confidential | Document ID

Select from Drop Down

Enter Short text of Services


Enter Material Group , Plant ,
tracking number (Employee)
and Department (planner group)

102

Select from Drop Down

| Aug 18, 2015

Select from Drop Down.


Search Tracking number
thru Vendor by Company
code

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 -Shutdown
Orders
Selection of PM03 -Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order (For Contractors)
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

103

Presentation Title | Confidential | Document ID

Go to Item Tab and Enter


Services number , Qty

Select from Drop Down

Go to Account Assignment Sub


Tab and Enter G/L Account
number and Cost center

Select from Drop Down

Check entries by Clicking


Button
Correct Entries If error massage
other wise Save the order
Navigate> SAP Screen

| Aug 18, 2015

4. CONDITION BASE MAINTENANCE PROCESS


BASIC PROCESSES

BASIC STEPS OF SHUTDOWN


MAINTENANCE PROCESS

1.
2.
3.
4.
5.
6.
7.

104

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

Presentation Title | Confidential | Document ID

Creation of Measuring Point

Selection of Measuring Point

Creation of Measuring Document &


Auto Notification

Creation of Entry List

Measuring Document Thru Entry list

Selection of M8 type Notification

Creation of Corrective Maintenance


Order Thru Notification

Execution of Orders

Confirmation of Orders

Technical Completion of Orders

| Aug 18, 2015

3. SHUTDOWN MAINTENANCE PROCESS


BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 -Shutdown
Orders
Selection of PM03 -Shutdown
Orders
Report of Shutdown Planning
Creation of Direct Purchase
Order (For Contractors)
Creation of Direct Purchase
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

Creation of Direct Purchase


Requisition (For Spare)
Go to T. code ME51N -Create
PR
Enter PR Type & Header note

Select from Drop Down

Account Assignment Type U &


Item Category leave Blank

Select from Drop Down

Enter Material & Reqd Qty

Select from Drop Down

Enter Del date , Plant &


Tracking number (planner
group)

Select from Drop Down

Check entries by Clicking


Button
Correct Entries If error massage
other wise Save the Purchase
request
Navigate> SAP Screen

105

Presentation Title | Confidential | Document ID

| Aug 18, 2015

4. CONDITION BASE MAINTENANCE PROCESS


BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type
Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders
106

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Creation of Measuring Point


Go to T. Code - IK01 -Crete
Measuring Point
Select Measuring Point Object IEQ
Select & enter Equipment
number
Select Relevant Measuring
Point Category (Except L & F)
Do not flag MP as counter for
CBM
Click on Enter Button
Write Measuring Position &
Description

4. CONDITION BASE MAINTENANCE PROCESS


BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type
Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders
107

Presentation Title | Confidential | Document ID

Enter relevant Characteristic


(UOM & decimal Place
defaulted)
Go to Additional data Button
header tool bar
Enter Upper range limit & Lower
range limit
Click on Enter Button
Main screen appears. Now click
on Save button to save MP
Navigate> SAP Screen

| Aug 18, 2015

4. CONDITION BASE MAINTENANCE PROCESS


Selection of Measuring Point

BASIC STEPS OF CONDITION


BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders
108

Presentation Title | Confidential | Document ID

Go to T. Code - IK07 Display


measuring Point : Measpoint
Selection
Enter Characteristics & MP
Category
Click Execute Button
Measuring point list appears
Select relevant Measuring point
Navigate> SAP Screen

| Aug 18, 2015

4. CONDITION BASE MAINTENANCE PROCESS


BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto Notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

109

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Creation of Measuring
Document
Go to T. Code IK11 - Crete
Measuring Document
Enter Measuring Point (as
selected)
Again Click on Enter Button
Enter MeasRdg as taken from
site
Again Click on Enter Button
A Massage Appears In case
Reading is Outside range
Again Click on Enter Button
Main screen of M8 type
Notification Generates
Automatically

4. CONDITION BASE MAINTENANCE PROCESS


BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto Notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

110

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Enter Reported by & click Enter


button
An Auto Notification of M8 type
Created
A massage comes for
Measuring document Created
Navigate> SAP Screen

4. CONDITION BASE MAINTENANCE PROCESS


BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type
Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

Creation of Entry List


Go to T. Code IK31 Measuring reading entry list:
Create
Click on Enter Button
Screen of Measuring reading
entry list: Create Appears
Enter entry list name &
Description
Enter measuring point numbers
As selected from drop down list
Click on Enter Button
All details of Measuring points
Appears in list
Now Click on Save Button
A Massage measurement
reading entry list xxx saved.
Navigate> SAP Screen

111

Presentation Title | Confidential | Document ID

| Aug 18, 2015

4. CONDITION BASE MAINTENANCE PROCESS


BASIC STEPS OF CONDITION
BASE MAINT. PROCESS
Creation of Measuring Point
Selection of Measuring Point
Creation of Measuring
Document & Auto notification
Creation of Entry List
Measuring Document Thru
Entry list
Selection of M8 type
Notification
Creation of Corrective
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders
112

Presentation Title | Confidential | Document ID

Creation of Measuring
Document Thru Entry list
Go to T. Code IK34
Collective entry of
MeasDocuments: Initial screen
Enter Entry list number
Click on Enter Button
Collective entry of
MeasDocuments: overview
screen Appears
Enter measuring Reading in
relevant measuring point field
Click on Enter Button
A Massage Appears In case
Reading is Outside range &click
again enter button. M8
Notification will generate
A massage appears as xx
Measuring document Created
| Aug 18, 2015

Navigate>
SAP Screen

5. REPAIR MAINTENANCE PROCESS


BASIC PROCESSES

1.
2.
3.
4.
5.
6.
7.

113

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

Presentation Title | Confidential | Document ID

BASIC STEPS OF REPAIR


MAINTENANCE PROCESS
Creation of M6-Notification
Selection of M6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

| Aug 18, 2015

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M 6-Notification
Selection of M 6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

Creation of M6 Notification

Manual Process

Go to T. Code IW21Create
Notification
Enter Notification Type

Select from Drill Down


H/L TO N/F Types

Do not Enter Notification


Number

System Generated

Click Enter Button


Notification Tab Screen Appears
Enter Notification Description
Enter Equipment / FL /
Assembly (as required)
Enter Reported By (Name)
Enter Code of STD TEXT
Attached

114

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down


as per requirement

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M2-Notification
Selection of M2-Notification
Creation of PM02-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification
Why-Why Analysis

115

Presentation Title | Confidential | Document ID

Main Work center/ Planner


Group etc Defaulted & can be
Changed If Required
Write Details of Job in Long Text
Go To Location Data Tab
Save the Notification
Navigate> SAP Screen

| Aug 18, 2015

All information Defaulted


from equipment master

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M6-Notification
Selection of M6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

Selection of M6 Notification
Go to T. Code IW28 Selection
of Notification
Flag check box Outstanding (as
reqd)
Enter Notification Date
Select Notification & Create
PM09 Type Order
Click Create button
of Order Tab
Navigate> SAP Screen

116

Presentation Title | Confidential | Document ID

| Aug 18, 2015

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M6-Notification
Selection of M6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

Create PM09 Type Order


Select Relevant Maintenance
Activity Type( Always RVN)
Go to Operation TAB
Select Relevant Work Center
(Type 0001)
Enter Number of Hours
Other Field automatically
Populated.
Select Relevant Work Center
for Operator & Enter Number of
Hours
Go to Component TAB & Attach
Required Material
Navigate> SAP Screen

117

Presentation Title | Confidential | Document ID

Select from Drill Down

| Aug 18, 2015

Select from Drill Down

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M6-Notification
Selection of M6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

118

Presentation Title | Confidential | Document ID

GO to IW38 & Search PM09


Type Order
Navigate> SAP Screen

| Aug 18, 2015

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M6-Notification
Selection of M6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

119

Presentation Title | Confidential | Document ID

Release Order & Issue Required


Material.
Carry out Repair Work As per
Request
Navigate> SAP Screen

| Aug 18, 2015

5. REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M6-Notification
Selection of M6-Notification
Creation of PM09-Order
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

120

Presentation Title | Confidential | Document ID

Further process of order will


remain same as explained in
process 1. Preventive
Maintenance
Navigate> SAP Screen

| Aug 18, 2015

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC PROCESSES

BASIC STEPS OF EXTERNAL REPAIR


MAINTENANCE PROCESS

1.
2.
3.
4.
5.
6.
7.

121

Preventive Maintenance
Break down Maintenance
Shut down Maintenance
Condition base Maintenance
Work shop Repair
External Repair/Services
Calibration

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Creation of PM09 Type Order


Selection PMEX Activity type
Creation of Purchase
Requisition
Creation Of Purchase Order
Confirmation of External Service
Entry Sheet
Technical Completion of Orders

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC STEPS OF EXTERNAL
REPAIR PROCESSES

Creation of PM09 Type Repair


Order

Creation of PM09 Type Order

Selection PMEX Activity type

Select Relevant Type


Maintenance Activity (Always
RVN, RWN)

Creation of Purchase Requisition

Select from Drill Down

Go to Operation TAB
Select Control Key As PMEX

Creation of Purchase Order


Enter Operation & Select It

Confirmation of External Service


Entry Sheet
Technical Completion of Orders

Click External Service Button


POP Screen Will Appear Enter
Material Group S 524,Purchase
Group, Tracking Number
Enter & GO to External
Processing operation Screen

122

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drill Down

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES

Creation of PM09 Type Order


Selection PMEX Activity type
Creation of Purchase
Requisition
Creation of Purchase Order
Confirmation of External Service
Entry Sheet
Technical Completion of Orders

Write Short Text of External


Service , Approximate Cost of
Repair, Quantity & Unit
Write Desired Vendor Code
Enter Cost Element & click

Select from Drill Down

Pop Screen of Purchase


request Will Appear Enter
Department (i.e Main Planner
group)

Select from Drill Down

Go back to Order main screen


Release it & Save Order
Go to Change Mode of Order &
select TAB Actual Data You will
get PR number
Navigate> SAP Screen

123

Presentation Title | Confidential | Document ID

| Aug 18, 2015

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES

124

Creation of PM09 Type Order


Selection PMEX Activity type
Creation of Purchase
Requisition
Creation of Purchase Order
Confirmation of External
Service Entry Sheet
Technical Completion of
Orders

Presentation Title | Confidential | Document ID

Go To Change Mode of PR
(ME52N)
GO To Document Overview &
Select Relevant PR
GO TO Customer TAB & Enter
all Required Deatils
Save PR
Navigate> SAP Screen

| Aug 18, 2015

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES

Creation of PM09 Type Order

Selection PMEX Activity type

Creation of Purchase Requisition

Creation of Purchase Order

Confirmation of External Service


Entry Sheet

Technical Completion of Orders

125

Presentation Title | Confidential | Document ID

MM Will Prepare Purchase Order


on PR

| Aug 18, 2015

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES

Creation of PM09 Type Order

Selection PMEX Activity type

Creation of Purchase Requisition

Creation of Purchase Order

Confirmation of External Service


Entry Sheet

Technical Completion of Orders

126

Presentation Title | Confidential | Document ID

MM Will Prepare Service Entry Sheet


You will Accept Service Entry Sheet

| Aug 18, 2015

6. EXTERNAL REPAIR MAINTENANCE PROCESS


BASIC STEPS OF
MAINTENANCE PROCESSES

Creation of PM09 Type Order

Selection PMEX Activity type

Creation of Purchase Requisition

Creation of Purchase Order

Confirmation of External Service


Entry Sheet

Technical Completion of Orders

127

Presentation Title | Confidential | Document ID

This Type of Order to be TECO


only When FINAL Service Sheet
Made.
Save

| Aug 18, 2015

III. MANAGING REPORTS

128

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

1. Object Class Statistics

[MCI1]

Object breakdown analysis in terms of Maintenance cost


Standard drill down (Key Figure)
Assembly
Construction year
Manufacturer
Material
Object class
Month

129

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

2. Manufacturer Analysis

[MCI2]

Object breakdown analysis in terms of Maintenance cost


Manufacturer wise.
Standard drill down (Key Figure)
Assembly
Construction year
Manufacturer
Material
Object class
Month

130

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

3. Location Analysis

[MCI3]

Object breakdown analysis in terms of Maintenance cost


Location wise
Standard drill down (Key Figure)
Assembly
Equipment
Functional Location
Location
Maintenance plant
Planner group
Planning plant
Plant section
Month
131

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

4. Planner Group Analysis

[MCI4]

Object breakdown analysis in terms of Maintenance cost


Planner Group wise
Standard drill down (Key Figure)
Assembly
Equipment
Functional Location
Location
Maintenance plant
Planner group
Planning plant
Plant section
Month

132

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

5. Single Object - Damage Analysis

[MCI5]

Object Damage analysis in terms of Damage & Causes,


Notification Type wise
Standard drill down (Key Figure)
Activity code
Cause of damage
CdGrp: damage cause
Code group: activity
Code group: damage
Damage
Equipment
Functional Location
Notification type
Month

133

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

6. Object Statistics

[MCI6]

This report provide the detail about the object statistics ( like
how many Equipment installed on a Function Location)
Standard drill down (Key Figure)
Object class
Manufacturer
Material
Construction year
Month

134

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

7. Breakdown Analysis

[MCI7]

This report provide the Breakdown Analysis information


(No. of B/D, MTTR, MTBR etc.).
Standard drill down (Key Figure)
Equipment
Functional Location
Object class
Month

135

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

8. Cost Analysis

[MCI8]

This report provide the Breakdown Analysis information


( No. of B/D, MTTR, MTBR etc.).
Standard drill down (Key Figure)
Equipment
Functional Location
Object class
Month

136

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

9. MTTR/MTBR Equipment

[MCJB]

This report provide :


MTTR/MTBR Analysis Equipment wise( No. of B/D, MTTR, MTBR
etc.).
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)

137

Presentation Title | Confidential | Document ID

| Aug 18, 2015

STANDARD REPORTS

10. MTTR/MTBR Functional Location [MCJC]


This report provide :
MTTR/MTBR Analysis Equipment wise
( No. of B/D, MTTR, MTBR etc.)
Month wise Breakdown Statistics ( No. of Notifications & B/D Hrs)

138

Presentation Title | Confidential | Document ID

| Aug 18, 2015

6.2 LIST OF DEVELOPED REPORTS

139

Presentation Title | Confidential | Document ID

| Aug 18, 2015

LIST OF DEVELOPED REPORTS:


No. following
PLANT REPORTS
S. The
are the Reports that are being developed in SAP:

140

List of Damage & Cause - Summary Report (Equipment wise)

Breakdown Matrix - Equipment ABC indicator & breakdown category wise

Work Center / Equipment wise Material Consumption

Equipment Schedule Maintenance Report

Breakdown why-why Analysis Report

PM order Skipped / Rescheduled Report

PM Order Slippage Summary Report ( Schedule Maintenance Slippage in


Plant VC)

Preventive Maintenance Work Request Report

Motor Failure Report

10

Inspection Check List

Presentation Title | Confidential | Document ID

| Aug 18, 2015

LIST OF DEVELOPED REPORTS:


S. No.

141

PLANT REPORTS

11

Maintenance Order / Operation Pending List

12

Section / Equipment Performance Report

13

Equipment Lubrication Consumption Report

14

Quarterly Lubrication Consumption Report

15

Purchase Request Tracking Report

16

Equipment Maintenance Cost Report

17

List of Service Entry Sheets

18

Work Center Wise Service Cost Report

19

Shutdown (consolidated) Planning Report (resources & cost)

Presentation Title | Confidential | Document ID

| Aug 18, 2015

LIST OF DEVELOPED REPORTS:


S.No.

142

MINES REPORTS

20

Tyre Life Summary Report

21

Equipment Position Wise Tyre Run Report

22

Tyre Maintenance Register

23

Oil Consumption Report

24

Oil, Filter & Lubricant Monitoring Report

25

Assembly Life Details

26

Sub assembly Performance Report

27

Breakdown Summary

Presentation Title | Confidential | Document ID

| Aug 18, 2015

143

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/1


Crete Measuring Point- IK01

Measuring Point Object

Select from Drop Down

Select Equipment

Select from Drop Down

Select Relevant Measuring Point Category

Flag

Select from Drop Down

for Measuring Point as a Counter

Write Measuring Position Description

Write Description of Measuring Point

Attach Relevant CHARACTERISTICS


144

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select From Drop


Down ,Always use
RUNNINGHOURS

CREATION OF MESURING POINT (COUNTER) FOR RUNHOURS Sheet 2/2


Press Enter ICON

Enter Counter Over Flow Reading

Maximum Reading of
Counter

Enter Annual Estimate Reading

It Will be drive Plan

Press ICON

For Save

Message : Measuring Point . Created

THE END

145

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MESURING POINT (LUB/Diesel Consumption) Sheet 1/2


Crete Measuring Point- IK01

Measuring Point Object

Select from Drop Down

Select Equipment

Select from Drop Down

Select Relevant Measuring Point Category

Always Select Category


L- for Lubrication &
F- Fuel Consumption

Flag

for Measuring Point as a Counter

Write Measuring Position Description

Write Description of Measuring Point

Attach Relevant CHARACTERISTICS


146

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select From Drop


Down , ,Always LUB
CONCOSUMPTION..

CREATION OF MESURING POINT(LUB/Diesel Consumption) Sheet 2/2


Press Enter ICON

Dont Enter Counter Over Flow Reading & Annual


Estimate Reading

Enter Save ICON Button

Message : Measuring Point ..Created

Press ICON

Dont Enter Counter Over Flow Reading & Annual


Estimate Reading

Enter Save ICON Button

Message : Measuring Point ..Created


The END
147

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MESURING POINT Sheet 1/2


Crete Measuring Point- IK01

Measuring Point Object

Select from Drop Down

Select Equipment

Select from Drop Down

Select Relevant Measuring Point Category

Select from Drop Down

Press Icon

Write Measuring Position Description

Write Description of Measuring Point

Attach Relevant CHARACTERISTICS


148

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select From Drop


Down

CREATION OF MESURING POINT Sheet 2/2


Press Enter ICON

Dont Enter Counter Over Flow Reading & Annual


Estimate Reading

Enter Save ICON Button

Message : Measuring Point ..Created

Press ICON

Dont Enter Counter Over Flow Reading & Annual


Estimate Reading

Enter Save ICON Button

Message : Measuring Point ..Created


THE END
149

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MESURING POINT DOCUMENT (IK11)


Creation of Measuring Document IK11

Select Desired Measuring Point

Enter ICON Button


for entering Reading

Next Screen will Appear

Enter Counter Reading or Difference of Counter

Press ICON Button

For Save

Message : Measuring Document ..Created.

THE END

150

Presentation Title | Confidential | Document ID

Select from Drop Down

| Aug 18, 2015

Counter should be
GREATER than
Previous Reading or
Difference not more
than 24 Hours

MAINTENANCE ITEM

WITH
TIME BASED PACKAGE

151

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Continued..

CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04


Create Maintenance Item IP04

Maintenance Plan Category

Maintenance Strategy

Select from Drop Down

Select from Drop Down,


Use Always GILDAY &
GILMON Only

Write Maintenance Item Description

Select from Drop Down

Enter Equipment

Write ORDER Type

This will be PM01


Always

Maintenance Activity Type

Select from Drop Down


(Use PVM Or AMC )

Attach Relevant Task List


152

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATEING MAINTENANCE ITEM (TIME BASE) Sheet -2/2


For Selection of Task List Use Icon

Task List Display Screen will Appear on Screen

Flag

General Task List

Press Icon ,
Lists

Screen will appear with List of Task

Select Appropriate Task List

Press Icon Enter

Press Icon

for Save

You will get Message : Maintenance Item ( System


Generated Number) Created. THE END
153

Presentation Title | Confidential | Document ID

| Aug 18, 2015

MAINTENANCE ITEM

WITH
PERFORMANCE BASED PACKAGE

154

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2


Create Maintenance Item IP04

Maintenance Plan Category

Select from Drop Down

Maintenance Strategy

ALWAYS Use PERFHR


For Plant,TPP,DG
Equipment & MINHR
For Mines Equipment

Write Maintenance Item Description

Select from Drop Down

Enter Equipment

This will be PM01


Always

Write ORDER Type

Maintenance Activity Type

Attach Relevant Task List


155

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drop Down

CREATE MAINTENANCE ITEM (PERFORMANCE BASE )Sheet -2/2


For Selection of Task List Use Button

Task List Display Screen will Appear on Screen

Flag

General Task List

Press Button ,

Screen will appear with Task List

Select Appropriate Task List

Press Icon

Press Icon

for Save

You will get Message : Maintenance Item ( System


Generated Number) Created
THE END
156

Presentation Title | Confidential | Document ID

| Aug 18, 2015

NAVIGATE > SAP SCREEN

Creation of Maintenance Item-[IP04]

157

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3

IP01

Create Maintenance Plan (IP01)

Maintenance Plan Number is System Generated


Number

Maintenance Category

Maintenance Strategy

Press Icon

Write Maintenance Plan Short Description

Go to TAB

For Assigning Maintenance Item

POP Screen will appear


Message : Possible Deletion of Data Entered When
Selecting
158

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drop


Down ,Always Use
GILDAY & GILMON

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 2/3


Display Maintenance Item :Selection Criteria Screen
Will Appear ,Write Equipment Number & Press Icon
Main Planner Group ,Main Work Center & other field
automatically Populated from Equipment Master
Main Planner Group ,Main Work Center & other field
automatically Populated
Main Planner Group ,Main Work Center & other field
automatically Populated from Equipment Master

Press Icon

Go to TAB Maintenance Plan Scheduling


Parameter

Write Scheduling Period :365 Days

Flag
159

Fro Completion Requirement

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 3/3

Press Icon

For Save

Pop Screen Will Appear For START DATE

Select Radio Button NO

Press Icon

Message will Appear on Screen : Maintenance Plan


.Created

The End

160

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MAINTENANCE PLAN (PERFORMANCE BASE) Sheet 1/3


Create Maintenance Plan (IP01)

Maintenance Plan Number is System Generated


Number

Maintenance Category

Maintenance Strategy

Press Icon

Write Maintenance Plan Short Description & Enter


Counter

Go to TAB

For Assigning Maintenance Item

POP Screen will appear


Message : Possible Deletion of Data Entered When
Selecting
161

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Select from Drop


Down ,Always Select
PERFHR For Plant,
DG, TPP & MINHR
For Mines

CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 2/3


Display Maintenance Item :Selection Criteria Screen
Will Appear ,Write Equipment Number & Press Icon
Main Planner Group ,Main Work Center & other field
automatically Populated from Equipment Master
Main Planner Group ,Main Work Center & other field
automatically Populated
Main Planner Group ,Main Work Center & other field
automatically Populated from Equipment Master

Press Icon

Go to TAB Maintenance Plan Scheduling


Parameter

Write Scheduling Period :365 Days

Flag
162

For Completion Requirement

Presentation Title | Confidential | Document ID

| Aug 18, 2015

CREATION OF MAINTENANCE PLAN (PERFORMANCE) Sheet 3/3

Press Icon

For Save

Pop Screen Will Appear For START Counter


Reading

Select Radio Button NO

Press Icon

Message will Appear on Screen : Maintenance Plan


.Created

The End

163

Presentation Title | Confidential | Document ID

| Aug 18, 2015

Anda mungkin juga menyukai