Consulting

Transforming

Project Name
Title

Enterprises

JK Cement
Calibration Inspection, Measuring & Test Equipments

Version

1.0s

Document ID

JK_BBP_PM_BP_0700_V1.0

Author

Akhilesh Kumar Singh

Reviewed By

XXXXXXX XXXXX

Date

01.11.2012

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

IMPLEMENTATION_BLUE PRINT
Business Process Details
Module

Plant Maintenance
Process
Sub Process /
No
Description

Sr
No
1.2

Calibration Inspection, Measuring & Test Equipments

Calibration Inspection, Measuring & Test
JK_BBP_PM_BP_090
Equipments
0

Calibration Inspection, Measuring & Test Equipments

Business Process Explanation

Explanation of Proposed Process

The calibration inspection combines functions from the Plant Maintenance (PM) and
Quality Management (QM) application components of SAP.
The equipment, for which you want to create a calibration order, must be created as a
piece of equipment in Equipment category Q (Test/Measurement equipments).
Maintenance orders provide a means for planning document and history for any
calibration inspection job. The Measuring equipment to be calibrated is mentioned as
reference object of order, Basic dates and maint. work center performing the calibration
inspection are defined in order header, calibration inspection related operations with
inspection characteristics are inserted in the operation page of order. The master
calibrator equipment can be assigned as a Production resource tool (PRT) in the
calibration inspection operations.
For calibration inspection the operations can not be feed directly into order but a
calibration task list must be created since inspection point and inspection characteristics
can be assigned to operations only in the task list and not in the order. This task list is
then inserted in the calibration order while creating the order directly, otherwise the task
list is assigned in the calibration plan.
On the other hand QM modules inspection lot functionality provides inspection results
recording facility for calibration inspection readings which are created as quantitative
inspection characteristics and assigned to order operations. Valuation and Usage decision
after result recording of inspection lot is also done in QM module.

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Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Inspection lot: In the Quality Management (QM) component, quality inspections are
processed on the basis of inspection lots. If you want to inspect a specific quantity of a
material or a piece of equipment, an inspection lot must be created in the system.
Inspection Lot is a request to a plant to inspect a specific quantity of material or pieces
of equipments or functional locations. An inspection lot is documented by an inspection lot
record in the SAP System.
Use
The system uses the inspection lot to record, process and manage information for a
quality inspection. This information includes:
Inspection processing data such as:
o Inspection lot origin
o Inspection date
o Processing status of inspection lot
Inspection specifications (for example, the task list or material specification according
to which the goods/equipment in the inspection lot will be inspected)
Inspection results:
o Recorded characteristic values
o Recorded defects
Usage decision (a decision that specifies whether the goods or equipment/ functional
location in the inspection have been accepted or rejected)
An inspection lot can be created manually by the user or automatically by the system.
Integration
Inspection lots can be created automatically by events triggered in other components of
the logistics supply chain. For example:
Goods movements in the Materials Management (MM) component (for example, goods
receipt)
Release of maintenance orders in the Plant Maintenance (PM) component.

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Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Cross Functional Reference(s):

Calibration inspection orders are linked or integrated with following SAP modules for
different purposes:
QM module: for inspection lot generation from calibration order, result recording and
usage decision for calibration inspection lots.
CO module: for order cost display and cost settlement to receivers e.g. cost center after
technical completion of order.
Calibration Inspection processing steps:
1. Create Task list for calibration inspection
First of all a task list for calibration inspection will be created according to
inspection requirements which will then be assigned in a Calibration plan or can be
inserted in the calibration order if order needs to be created directly.
The task list will be general task list with inspection points for equipment. Required
inspection characteristics will be assigned to the task list operations.
2. Order creation :
There will be two scenarios for creating calibration order:
1.

With reference to the notification(s):

Whenever a notification (Maint. request) will be received from plant that a

particular measuring equipment is showing incorrect reading and needs calibration,
then a calibration order (type PM06) will be created w.r.t. that notification for doing
calibration of that measuring equipment.
2.

Automatically from Maintenance plans:

Calibration orders will be created automatically through Maintenance plans,

mainly Calibration plans or Shutdown plans, on their due dates as per the schedule
decided for these jobs.
For the first case, calibration can be created by any user having authorization to
create the orders and following data will be planned and entered while creating the
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Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

calibration order with reference to the notification:

3. Equipment (to be calibrated) in reference object
Insert correct calibration task list in the order operations.
Manual assignment of any permit(s), if required, like process isolation or control
isolation/system bypass, for carrying out calibration operations on equipment.
Save order.
For the second case if the order is created from a shutdown plan, then the
Revision of that shutdown, if any, should be assigned at order header
2. Maintenance order release/ putting in process:
An authorized person like Shift Engineer will check the planned order and then
release the order to give the go ahead for executing the planned operations.
Before releasing any automatically created calibration order from a Shutdown plan,
the Revision of that shutdown, if any, should be assigned at the order header before
releasing it.
An order can not be released until all the permits assigned to the order, if any, are
issued by authorized person(s) after checking and insuring the required conditions at
the job site, required by the permits. So all the permits should be issued before
releasing the order.
When order is released following activities take place in background:
PRT availability is checked and message is issued if PRT is not available for the
order dates.
Planned cost is calculated based on the resources planned in the order.
Order is scheduled according to the availability of work hours capacity in the maint.
work center.
A calibration inspection lot is generated from the order, based on the inspection
characteristics assigned in the calibration task list operations. The system status
ILAS (Inspection Lot Assigned) in order confirms this event.
Following activities can be performed after order is releasedResult recording can be done for the calibration inspection lot generated through
order
Usage decision can be given to the calibration inspection lot
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Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Time confirmation of operations can be done after execution of calibration

inspection operations
Orders can be technically completed (TECO)
Order cost settlement can be done.
3. Order operations Execution:
This involves following steps
Collection the PRT (master calibrator equipment), if any
Execution of planned calibration inspection operations
Result recording of inspection readings in the inspection lot.
When the inspection results are saved, system will give automatic valuation for
the inspection which can be edited manually if required. At the same time the time
confirmation of calibration operations can be done from the same screen.
Usage Decision: Usage decision for the inspection lot will be given manually based
on the valuation that whether the calibrated equipment is usable or not.
If UD is given for not usable then system proposes a status change for that
equipment so that the equipment status will become NPRT (PRT not usable). You
can edit that proposal to specify that the status should not be changed.
Simultaneously system gives you the option of modifying the Cycle Modification
factor of calibration plan if the order was generated from a plan.
When the UD is saved, the calibration order will also be technically completed
(TECO) in background, as a result of follow-on function.
4. Settlement and Business completion :
After technical completion, the order will be settled and its Business completion can
be done.

1.3

Sr

Special Organizational Considerations

NA

Gap Analysis

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Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

No
2.1
2.2
2.3
Sr No
3.1
3.2

Gap Identified in proposed solution against Requirements & Expectations

Not applicable
Impact of Requirement
Not applicable
Solution Proposed
Not applicable
Topics
Changes Management Issues
Not Applicable.
Description of Improvements
Online history of calibration inspection of measuring equipments and master
calibrator equipments will be available using the calibration orders.
Calibration scheduling overview list of the measuring equipments or Master
equipments which are covered by any plan can be seen from their equipment
masters itself. There you can see all the past and future schedule dates of
calibration inspection including last calibration date and next calibration due
date according to the schedule.
If calibration inspection of any equipment fails then its system status in
equipment master record, changes to NPRT (not usable) automatically while
you save the usage decision of its calibration inspection lot as not usable.
This status tells that the equipment is not valid for use. This status will be
removed automatically in the next successful calibration inspection after
repairing or correcting the settings of the measuring equipment
when you save the usage decision as usable.
This gives the online validity status of any measuring equipment or master
calibrator equipment.
You can modify the cycle length of calibration plan by changing cycle
modification factor at the time of Usage decision saving.
This is useful for testing purpose temporarily for evaluating the optimum
interval for calibration of any equipment over the period of time.
The calibration order operation time confirmation can be done simultaneously
at time inspection result recording is saved for the calibration inspection lot.
Similarly calibration order is technically completed, automatically in
background, at the time of usage decision saving for the calibration
inspection lot.
This eliminates the need of doing completion confirmation and technical
completion of order separately and reduces considerable time of user in

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Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

processing a calibration in the system.

Sr
No
4.1

Topics
Interface / Enhancements considerations
Not Applicable
Reporting considerations

4.2

Sr. No.

Reports
T- Codes
IP16
IP18
IP19
IP24
IP30

4.3

1.
Calibration Plan selection criteria
2.
Maintenance item selection criteria
3.
Graphical Scheduling Overview
4.
Calibration Scheduling Overview
5
Dead line Monitoring for Calibration Plans
Authorization considerations
As per organizational needs, not finalized yet. Authorization matrix is being prepared
separately.

Business Process Signoff

Module

Plant Maintenance
Process
Sub Process /
No
Description

Calibration Inspection, Measuring & Test Equipments

Calibration Inspection, Measuring & Test
JK_BBP_PM_BP_0700
Equipments
Calibration Inspection, Measuring & Test Equipments

Copyright 2011 JKT

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