Preventive

Maintenance

Flow Chart to Create Maintenance Schedule in

SAP
Maintenance
Maintenance Task
Maintenance Item
Maintenance Plan
Strategy
Defines the rules
for the sequence
of the
maintenance

List
Describes
the list of
individual
maintenance
activities to be
performed
periodically

Describes
maintenance object
and inspection task
to be done

Describes the
maintenance object and
inspection task to be
performed and date and
scope of the
maintenance

Complete Order

Execute Order

Create Order

Schedule
Maintenance Plan

Activity Report
Notification

Maintenance Strategy
Defines the rules for the sequence of planned maintenance work
Contains general scheduling information
Can be assigned to as many maintenance task list (PM task list) as needed
Each operation task list may have different package/duration of cycle
Contain the duration of cycle in which the individual work should be performed

T-code = IP11
Maintenance Strategy
Long
Medium
Short

Yearly strategy 1 to 5
years
Monthly strategy 1 to 12
months
Daily strategy 1 to 30
days

Maintenance Scheduling Indicator

Time e.g. once per 20 days
Time Key date e.g. every 7th day of the month
Time Factory calendar e.g. every 20 working day
Activity e.g. every 1000 working hours (will not be used in U2K2)
Current Date

21. August, 2005

Current Date

21. August, 1999

Current Date

21. August, 1999

1st planned
date

20. September, 2005

1st planned
date

21. September, 1999

1st planned date

02. October, 1999

2nd planned
date

20. October, 2005

2nd planned
date

21. October, 1999

Time: once every 30 days

3rd planned
date

19. November, 2005

2nd planned date 15. November, 1999

Time Key Date: on date 21st

3rd planned
21. November, 1999
of
that
month
date

3rd planned date 02. January, 2000

Time Factory Calendar :

every 30 working days

Call Horizon
Defines when a maintenance order should be make, in relative
to the maintenance cycle
Specifies as a percentage, when a manufacturing order should
be created for a calculated maintenance date
Which is, time interval between the confirmation date and the creation
of maintenance order
Example: the maintenance cycle is 250 days
Call horizon of 0% system creates the maintenance order right now
Cal horizon of 80% system creates the maintenance order 200 days from now
Call horizon of 100% system creates the maintenance order when the system
reaches the planned date

Shift Factor
Manages the next planned date shift when we confirm too
late or too early
There are 2 shift factors in the Maintenance Planning:
Early completion confirmation
Late completion confirmation

The shift factor only applies once the maintenance plan has already
been scheduled, and when the difference between the planned date
andDate
actual
dateNext
lies
outside
the
tolerance range.
Planned
Confirmed
Planned
Date
Shift Factor
01.08.1995

16.08.1995

01.09.1995

0%

16.09.1995

100 %

08.09.1995

50 %

Tolerance
Tolerance defines the range of late and early confirmation
There are 2 types of tolerance
+ Tolerance for late confirmation
- Tolerance for early confirmation

Percentage of the smallest cycle in the maintenance strategy,

which we have assigned in maintenance plan
For Example:
The smallest cycle in the maintenance strategy, which you have
assigned to the maintenance plan is 30 days.
You have defined a tolerance of 10% in the case of early completion
confirmation.
This produces a tolerance of 3 days.
If completion is confirmed no more than 3 days before the planned
date, the system does not consider this deviation when calculating the

Maintenance Plan
Single cycle plan vs Strategy Plan
Operation
#
010
020
030

Cycle

All operation every 3

month

...

In single cycle plan, we

have
one cycle for all operation
in
the task list (simple)
This is not generally used
in U2K2

Operation
#
010

Cycle
Every 1 Month

020

Every 2 Month

030

Every 6 Month

...

Every n Month...

In strategy plan, we
can have
different cycle for each
operation

Maintenance Task List

Sequence of individual maintenance activities that must
be performed repeatedly within company
3 types of Maintenance Task List:
Function Location Task List
Equipment Task List
General Task List (Most common and preferred in U2K2, to
minimize the needs of creating task list for every equipment)

T-Code = IA05

Maintenance Task List

Process Maintenance Task List Structure

Each operation in maintenance task list will have control key:

o

PM01 : Internally Processed Operation

PM02 : External Service

PM03 : Not Relevant for Costing

For external service you will have to maintain purchasing data.

You also can put components required:

Stock item (item category: L)

Non-stock item (item category: N)

For non-stock item, you will have to maintain purchasing data

Task List
Group
20123
(for pump)

Group
Counter 1
(for liquid
pump)

Operation 010
Operation 010
Operation 010

Group
Counter 2
(for solid
pump)

Operation 010
Operation 010
Operation 010

10

Material BOM

3 Types of BOM (Bill of Material)

Functional Location BOM
Equipment BOM
Material BOM
Material BOM gives a list of individual parts with respective quantities for a
material / assembly
Material number is given to each material BOM
It is for use with multiple equipment BOM/Functional Location BOM of the same
material
It is using material type IBAU (Maintenance Assembly)
Use Material BOM if BOM components are general for similar type of Equipments