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Performance-based Maintenance Planning

Business Process Counters and Measurement Documents Performance-based Maintenance Plan Scheduling Customer Exits

SAP AG

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Business Process
50,000 l

Flow

100,00 0l

What must be maintained after how much throughput?

SAP AG

Different maintenance workshould be performed on the pumps at your company based on their throughput. Hence, for example, a safety check should be performed after 50,000 litres and all the seals changed after 100,000 liters. Preventive maintenance can be planned and performed using a performance-based strategy and regularly entered counter readings. The calculated maintenance dates are adjusted automatically based on the counter readings entered.

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Unit Objectives:
At the conclusion of this unit, you will be able to:
Create and set counters Generate and display measurement

documents
Create a performance-based maintenance

plan
Perform scheduling on the basis of

performance

SAP AG

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Topic Overview
Business Process Counters and Measurement Documents Performance-based Maintenance Plan Scheduing Customer Exits

SAP AG

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LO810

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Creating a Counter
Characteristic: Flow 015324 Annual performance: 720,000 liters

SAP AG

Counters are represented in the SAP System as a special form of measuring points. Meauring points are always created with reference to the object (for example, equipment), but are managed in their own master record in the system. A characteristic is assigned to the counter (for example, operating hours, flow and so on). The characteristic is always used linked with the respective characteristic unit (for example, hours, liters).

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Entering an Initial Document

001500

Measuring time: Characteristic: Unit:

2.01.98 Op. hrs Hrs.

Counter reading: 1500 Difference: 1500

Total counter reading: 1500

R

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Topic Overview
Business Process Counters and Measurement Documents Performance-based Maintenance Plan Scheduling Customer Exits

SAP AG

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LO810

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Performance-based Maintenance Strategy

1997

Scheduling indicator Performance Strategy

100 ,00 0l 50, 000 l 50, 000 l 50, 000 l

Package definition

SAP AG

Performance-based maintenance - Example: Specific maintenance work should be performed on the pump after 50,000, 100,000 and 150,000 liters of throughput. For performance-based maintenance, a strategy is defined with the scheduling indicator Performance (Activity). A strategy unit is assigned (for example, liters - for preventive maintenance which is based on the volume of throughput). In the strategy, maintenance packages are defined which use the same parameters as in time-based maintenance. For example, for the cycle length, a specific throughput quantity could be entered (for example, 50,000 liters).

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Creating a Performance-based Strategy Plan

Task list

Operation 10 Operation 20 Operation 30 Operation 40 Operation 50 Operation 60 Operation 70

100,00 0l

50,000 l

Strategy
50, 50 0 00 l

100 ,,00 00 l 50, ,000 00 l 50, ,000 0 l

SAP AG

Maintenance packages define the frequency at which specific operations are executed. Maintenance packages can be assigned to the operations of a task list. Maintenance packages are part of a maintenance strategy. Important parameters for a maintenance package are: - Package number - Description - Cycle length - Unit of measurement - Hierarchy If two packages are due on the same date, the hierarchy determines which package is performed. - Offset The offset determines the first due date for a package. - Preliminary/follow-up buffer The preliminary or follow-up buffer specifies the tolerance over which the intended start and end dates for a package can range.

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Topic Overview
Business Process Counters and Measurement Documents Performance-based Maintenance Plan Scheduling Customer Exits

SAP AG

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LO810

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Scheduling Functions
Last actual date, Last maintenance package

Cycle start

Restart
Manual call

Start in current cycle

Schedule
Last a ctual date

Next planned date, Next maintenance package

SAP AG

Restart: This is the function that is normally used to start a maintenance plan for an object that is just being brought into service, or for which preventive maintenance needs to be carried out. Schedule: This is the function that is normally used to call up the next maintenance order after the last maintenance order has been completed. Start in current cycle: You can restart scheduling for your maintenance plan in the current cycle. This function could be used in the situation where you previously managed maintenance activities without a computer system, or with a system other than SAP R/3. The maintenance strategy that you have assigned to your maintenance plan may have, for example, three packages: monthly, every 4 months and every 6 months. Instead of starting scheduling with the "monthly" package, you specify that scheduling should start with the 6-monthly package, and the date on which preventive maintenance was last carried out. Manual call: If you also want to schedule a maintenance plan call for a particular date, you can schedule this date manually. You use a manual calls to insert additional dates without influencing normal scheduling. You enter the following data for this: - Call date - Due maintenance packages

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Calculation of Planned Dates

Calculated planned date

Annual performance 36,500 liters

8 5.9 3.1

8 1.9 0.0 1

Cycle start

Cycle 20,000 liters

SAP AG

The scheduling of a performance-based strategy plan is based on the estimated annual performance and the respective cycles. Starting from the current counter reading, a planned date is calculated from these two values. Example: Estimated annual performance: 36,500 liters Internal calculation of daily performance: 36,500 : 365 days = 100 liters per day Planned date for a cycle of 20,000 liters: 20.000 : 100 = 200 days, This means that, beginning from the cycle start, the first planned date is set after 200 days.

The planned dates can still be calculated based on, for example, the last five counter readings.

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Scheduling Functions (1)

Liters 40,000

Linear development of throughput

20,000

Estimated annual performance = 36,500 liters

Months 6 12

Calculated planned date

SAP AG

A planned date is calculated on the basis of the estimated annual performancein dependency with the cycle.

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Call Horizon
Call horizon 90% = 18,000 liters

Order Calculated planned date

98 15. 03.

98 01. 10.

Cycle start

Cycle 20,000 liters

SAP AG

The call horizon is specified as a percentage and refers to the duration of the cycle. It specifies when an order should be created, with reference to a calculated maintenance date. Example: - Annual throughput quantity: 36,500 liters - Results in a daily throughput quantity of 100 liters - Selected cycle: 20,000 liters - Results in a calculated cycle duration of 200 days - Cycle start is a counter reading of 0 liters on 03.15.98 - Results in a planned date on 10.01.98 - Call horizon should be 90%, meaning that the order is not created on 10.01., but on 09.11. (therefore, after 180 days). Caution: The example above is a calculation of planned dates without taking measurement documents into consideration. If measurement documents are entered, the planned dates are recalculated on the basis of these measurement documents (see next page). Note: If no value is specified for the call horizon when scheduling the maintenance plan, the system assumes that the call horizon is 0%. This has the result that a call is made immediately (meaning an order is created) when the maintenance plan is started, independent of the counter reading. If the duration of the cycle is to be used, it is recommended to set a call horizon of 100%.

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Scheduling Functions (2)

Liters 40,000

Linear development of throughput

20,000

Estimated annual performance = 36,500 liters

Call horizon 90% = 18,000 liters

Months 6 12

Call
SAP AG

Calculated planned date

If you are working with a call horizon of 90%, the calculated planned date also appears in the list of scheduled calls. The call, (creation of the order), occurs earlier: Example: Cycle start: 03.15.98 Estimated annual performance: 36.500 liters Calculated daily perfomance:100 liters Resulting planned date: 10.01.98 Call horizon: 90% Call date: After 180 days, therefore, 09.10.98

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Scheduling Functions (3)

Liters 40,000

Counter readings according to measurement reading entry

20,000

Call horizon reached!

Estimated annual performance = 36,500 liters

Call horizon 90% = 18,000 liters Call date

Months 6

Potential call
SAP AG

Recalculated 12 planned date on the basis of measurement document

If a measurement document is entered, a new planned date is calculated on the basis of this measurement document, taking into consideration the estimated annual performance. If a call horizon is also being used, the call is made earlier correspondingly (see previous page). It a measurement document reaches the call horizon, this results in an immediate call

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Topic Overview
Business Process Counters and Measurement Documents Performance-based Maintenance Plan Scheduling Customer Exits

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Customer Exits
IPRM0002

SAP AG

In the case of strong seasonal variances (for example, in agriculture), calculation of planned dates can be structured using the customer exit IPRM0002 according to your own specifications. The documentation for this customer exit can be called up using transaction SMOD.

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Summary (1)
Performance-based maintenance is based on

the entry of counter readings.

Every technical object which should be

regularly maintained based upon performance must have a measuring point (special form: counter) to which a characteristic is assigned.
The planned date in the maintenance plan is

calculated based on the estimated annual performance and the chosen strategy.

SAP AG

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