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Preventive

Maintenance
Preventative Maintenance
• What is a Preventive
Maintenance?

– Preventive Maintenance is
planned maintenance that is
designed to improve
Equipment life and avoid
breakdowns on the plant.
Preventive Maintenance: Basics

 Basics
 Task list
 Single cycle plan
 Strategy plan
 Maintenance plan scheduling

 SAP AG 1999
Types of Preventive Maintenance

Preventive
maintenance

Time-based Performance-based Condition-based


2000
30 40 50
20 60
10 70
80
Pressure
Pressure
Temperature

Thickness

 SAP AG 1999
Preventive Maintenance
• An Equipment can require maintenance
activities to be performed based upon either
time or a certain condition being met.

mo4nWthks
1

External visual inspection

Wks 1
2

Internal visual inspection


52wks

Check gear teeth for wear


Preventive Maintenance: Phases and Roles

Phase Contents Roles

1 Task list
Create task lists for different
objects
Maintenance
planner

2 Maintenance Create maintenance plans


Maintenance
planner
plan

Maintenance
3 Schedule Schedule maintenance plans
planner

Maintenance Maintenance
4 order
Process maintenance orders
technician

Technical Technically complete Maintenance


5 completion maintenance orders supervisor

 SAP AG 2001
Preventive Maintenance: Task List

 Basics
 Task list
 Single cycle plan
 Strategy plan
 Maintenance plan scheduling

 SAP AG 1999
Task List

hat?
W

Operations

Maintenance work centers

Material components

Production resources/tools
hy?
W Maintenance packages

For
Forpreventive
preventivemaintenance
maintenance
(maintenance
(maintenance andinspection)
and inspection)
For
Forroutine
routinemaintenance
maintenance
(planned repairs)
(planned repairs)

 SAP AG 1999
Maintenance Task Lists: Structure

Planner group
Task list header

Maintenance 3m
o
strategy 6 mnths
ont
h
12 s
mo
nth
s

Work center
Operation 10
Operation 20
Operation 30
Components

Production
resources/tools

 SAP AG 1999
Maintenance Strategy
• What is a Maintenance
strategy?

– A Maintenance Strategy
defines the frequency and
scheduling data for Planned
Maintenance activities.
Maintenance Strategy
2000
Package
definition

Scheduling parameters

Time

4 Week 12 Weeks 24 Weeks

Strategy

What is a Maintenance Package?


Maintenance Package
•Maintenance packages define the frequency at which specific
operations are executed. You can assign maintenance packages to
the operations in a task list.
•Maintenance packages are part of a maintenance strategy.

Package number

Description
Wm
ee
oknsth1s2
3
Cycle length

Hierarchy
Unit of Offset
measurement
Maintenance Package Hierarchy
Same hierarchy levels
12 Wk
s
Strategy
24
Wk
10 s

24 Wk
s 12 12
wk 12 wk
s wk s
s

10

Different hierarchy levels


12 Wk Strategy
s
24
Wk
s

10
24 Wk
s
12
W ks
X 12
W ks
12
Wk
s

20
Preventive Maintenance: Single Cycle Plan

 Basics
 Task list
 Single cycle plan
 Strategy plan
 Maintenance plan scheduling

 SAP AG 1999
Single Cycle Plan: Business Process

1999 94 96

98
1997
2000

KED
H EC ears
C 2y
ry
eve
Inspection of
I must perform the "Portable fire extinguishers"
same inspections at
regular intervals.

 SAP AG 1999
Single Cycle Plan
• Simple and quick way to create a preventive
or inspection plan.
• Includes only one cycle or frequency.
• Can be either time or performance based.
• All operations on the Task list will be
performed.
• More than one Maintenance item can be
included.
What is a Maintenance Item -- ?
Maintenance Item
• Every Maintenance plan will have at least one Maintenance
item.
• A Maintenance item can only belong to one maintenance plan.
• The Maintenance item contains the following information:
– Description (Becomes the Maintenance order description)
– Technical object
– Task list
– Planning Data
• Order or notification type
• Planner group
• Priority
• Main work center
• Maintenance activity type
– Object list
Maintenance Item (Cont.)
• A Maintenance item can contain more than one Technical
object.
• The Technical object can be an Equipment, Functional
location or Assembly.
• The Maintenance item description becomes the description of
the Maintenance notification or order.
• For Maintenance items that are part of a Strategy based plan
a Maintenance strategy must be included within the item.
• The Task list for this Maintenance item will also need to be
linked to the same Maintenance strategy.
Single Cycle Plan Steps
• Three steps in creating a single cycle plan.
Task List

Task List Group


PRTs Maintenance Item
Components
Technical Object
Task List
Planning Data Maintenance Plan

Maintenance Item
Scheduling Param.
Cycle (Frequency)
Scheduling Data and Maintenance Item

Interval (cycle)

Maintenance plan 3 months

Scheduling data Maintenance item

Maintenance item

Reference
object
Task list
(optional)
Responsibilities/
Planning data
 SAP AG 2001
Using a Task List to Include an Operation List

Maintenance plan
Task list

Scheduling data

0010 Switch off


Maintenance item
0020 Safety check

0030 External visual check

0040 Change seal

0050 Exchange H9 casing


0060 Check Z7 wire

 SAP AG 2001
Single Cycle Scheduling

1
Maintenance plan

Scheduling data

Planned Date

Maintenance item

04 20 04 20 04
3 . 20 0 6. 0 9.
15.
0 15. 15.

Cycle Start Cycle


Weeks 12
Preventive Maintenance: Strategy Plan

 Basics
 Task list
 Single cycle plan
 Strategy plan
 Maintenance plan scheduling

 SAP AG 1999
Strategy Plan: Business Process

1 mon
th

External visual inspection

3 mon
ths

Internal visual inspection


1 year

Check gear teeth for wear

Which parts must be


maintained at which
intervals?

 SAP AG 1999
Maintenance Plan Steps

Strategy

Maintenance Task List


Packages
Task List Group
Maint. Packages
Maintenance Item
The Task List checks Maint. Strategy
the Package to Maint. Strategy
ensure the Strategy
Technical Object
Maintenance Plan
still exists.
The Item checks the Task List
Task List to make Maint. Strategy
ensure that the
same Strategy is
Maintenance Item
The Plan checks the Scheduling Param.
used
Item to make ensure
that the same Strategy
is used
Task List and Maintenance Strategy

Strategy 6m
Task list on
th s

3m 3m 3m
on on on
th s ths th s

0010 Switch off


0020 Safety check
0030 External visual check 3 mon
0040 Change seal
ths
0050 Exchange H9 casing
0060 Check Z7 wire

6 mon
ths

 SAP AG 1999
Creating a Time-Based Strategy Plan

Maintenance plan Task list

Scheduling data

0010 Switch off


0020 Safety check

0030 External visual check


Maintenance item
0040 Change seal

0050 Exchange H9 casing

0060 Check Z7 wire

3 m on
ths
6 m on
ths
Strategy 6m
on
th s

3m 3m 3m
on on on
th s th ths
s

 SAP AG 1999
Preventive Maintenance: Maintenance Plan Scheduling

 Basics
 Task list
 Single cycle plan
 Strategy plan
 Maintenance plan scheduling

 SAP AG 1999
Schedule Maintenance Plans

Cycle start
New Last actual date
Last maintenance

start package

Start in
Manual current
call cycle *
Next
planned date
Schedule
Next Last
ac tual d
maintenance ate
package

* Only for strategy plan


 SAP AG 2001
Cycle Start and Planned Date

1
Order 901760
Maintenance plan
Order exactly
on planned date?

Scheduling data

Planned date

Maintenance item

000 000
1. 2
0 4.2
0
15. 14.

Cycle
Cycle start
3 months

 SAP AG 2001
Maintenance Scheduling Overview

Maintenance item report, sorted by equipment (no.)


1999
... as a graphic
1998

With maintenance plan simulation


With/without details

... or as a list
With display variants
With general list viewer

 SAP AG 1999