Vous êtes sur la page 1sur 163

Business Consulting Services

SAP PM Module Training


SAP R/3

PLANT MAINTENANCE SYSTEM

2 Presentation Title | Confidential | Document ID | Mar 15, 2017


PLANT MAINTENANCE SYSTEM

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

3 Presentation Title | Confidential | Document ID | Mar 15, 2017


I. MANAGING MASTERS

4 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS CONTENTS OF MAINTENANCE


OF MASTERS
1. Functional Locations
Plant
2. Equipment Master Main Planner Group
3. Class & characteristics Plant Section
4. MICs Main Work Center
5. Work Center Cost Center /Internal Order
Category
6. Measuring Point
Company Code
7. Task List Master
Strategy
8. Maintenance Item UOM
9. Maintenance Plan

5 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS CONTENTS OF MAINTENANCE


OF MASTERS
1. Functional Locations
Function Location
2. Equipment Master
Structure
3. Class & characteristics
4. MICs Function Location Category
5. Work Center
Plant
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

6 Presentation Title | Confidential | Document ID | Mar 15, 2017


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

7 Presentation Title | Confidential | Document ID | Mar 15, 2017


FUNCTION LOCATION STRUCTURE
Description Code
Structure Indicator GIL
Structure Indicator Text GIL Cement Division
Edit Mask AAA-AANN-AAX-AAX-XXX-XXXXX
Hierarchy Levels 1 2 3 4 5 6

Example
Hierarchy Edit Mask Code Description
Level
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

8 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS CONTENTS OF FUNCTIONAL


LOCATION MASTER
1. Functional Locations Function Location Structure
2. Equipment Master
Function Location Category
3. Class & characteristics
4. MICs Plant
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

9 Presentation Title | Confidential | Document ID | Mar 15, 2017


FUNCTION LOCATION CATEGORY

Category Description

C Colony Functional Locations


G General Functional Locations
H Hierarchical
M Plant & Machinery F Locations
N Mines Functional Locations
O Office Functional Locations
T Power Generation F. Locations
U Utility Functional Locations

10 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF MAINTENANCE


OF EQPT MASTER

1. Functional Locations Equipment Category


2. Equipment Master Plant
3. Class & characteristics Functional Location
Main Planner Group
4. MICs
Tech. Object Type
5. Work Center Plant Section
6. Measuring Point Main Work Center
7. Task List Master Cost Center /Internal Order
Company Code
8. Maintenance Item Class
9. Maintenance Plan Warranty data

12 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


EQUIPMENT CATEGORY

CATEGO EQUIPMENT EXAMPLES


RY
A AUTOMOBILE CARS/JEEP/MOBILE VAN

C CIVIL OBJECTS BUILDINGS/CIVIL EQUIPMENTS


D DUMMY EQUIPMENTS USED IN SYSTEM ONLY FOR RUN HOUR
TRANSFER. NOT TO BE USED
E ELECTRICAL EQUIPMENTS MOTORS/TRANSFORMERS/SWITCH
GEARS
I INSTRUMENT EQUIPMENTS RTDS/PROXIMITY SWITCHES/FIELD
INSTRUMENTS/PANELS
M MECHANICAL EQUIPMENTS GEAR BOXES/DPC/DBC/BELT
CONVEYORS
N MINES EQUIPMENTS SHOVELS/DUMPERS/DRILLING
MACHINES

14 Presentation Title | Confidential | Document ID | Mar 15, 2017


EQUIPMENT CATEGORY

CATEGOR EQUIPMENT EXAMPLES


Y

P PROCESS EQUIPMENTS CYCLONES/HOPPERS

Q QC TEST EQUIPMENTS CUBE TESTING MACHINE /


COMPRESSIVE STR MACHINE

R PRODUCTION RESOURCES/TOOLS CRANES

T TPP/DG EQUIPMENTS TURBINE/ECONOMISER/BOILER

U 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 | Mar 15, 2017


EQUIPMENTS CATEGORY & NUMBER RANGE

Number
Number range
Category Description Range
From
To
M Mechanical Equipments 10000000 19999999
E Electrical Equipments 20000000 29999999
I Instrumentation Equipments 30000000 39999999
P Process Equipments 40000000 49999999
T TPP & DG Equipments 50000000 59999999
N Mines Equipments 60000000 69999999
Automobiles Equipments
A 70000000 79999999

C Civil Objects & General Equipt. 80000000 89999999


S Safety Equipments 90000000 99999999
Q QC Test Equipments 1000000 1999999

16 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 :

ME_GEARBOX Gear Box

EL_MOTORS Electrical Motors

ME_FANS Fans

17 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


PLANT SECTION

Plant Section is a division of Maintenance Plants into Production


Areas.

Plant Category Description

GC01
RM1 Raw Mill -1

GC01
CO1 Coal Mill -1

GC01
KL1 Kiln -1

GC01
CM1 Cement Mill -1

GC01
PP1 Packing Plant -1

20 Presentation Title | Confidential | Document ID | Mar 15, 2017


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

PLANNER GROUP = MAIN WORK CENTER + PLANT SECTION

MCM = Mechanical + Cement Mill


ECM = Electrical + Cement Mill
ICM = Instrumentation + Cement Mill

21 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 Electrical Instrumentation Process

22 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF CLASS &


CHARACTERISTICS MASTERS

1. Functional Locations
Class Type
2. Equipment Master
Class Group
3. Class & characteristics
Characteristics Group
4. MICs
Unit of Measure for
5. Work Center
Characteristics Master
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

24 Presentation Title | Confidential | Document ID | Mar 15, 2017


CLASS
Classes are :

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.

25 Presentation Title | Confidential | Document ID | Mar 15, 2017


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:

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

26 Presentation Title | Confidential | Document ID | Mar 15, 2017


CLASS

Mechanical Electrical
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 | Mar 15, 2017


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 | Mar 15, 2017


NAVIGATE > SAP SCREEN

Display of Class List [CL03]

Find Object in Class- [CL30N ]

29 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF MICs MASTER

Plant
1. Functional Locations
2. Equipment Master Range of Characteristics Value

3. Class & characteristics


4. MICs
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

30 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


NAVIGATE > SAP SCREEN

Find out The Maintenance Inspection Characteristics prepared-[QS24]

32 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF WORK CENTER


MASTER

1. Functional Locations
Plant
2. Equipment Master
Work Center Category
3. Class & characteristics
Control Key
4. MICs
Cost Center
5. Work Center
Work Dimension - Time
6. Measuring Point
Work Unit
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

33 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 Mechanical Permanent
0022 Mechanical Contractor
Example : M1F1W3K, MC1F1W3K etc.

Codification Logic :

M1F1W3K = Mech. Permanent / 1 Fitter /1Welder / 3 Khalasi


MC1F1W3K = Mech. Contractor / 1 Fitter /1Welder / 3 Khalasi

34 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF MEASURING


POINT MASTER

1. Functional Locations
Equipment Master
2. Equipment Master
Function Location Master
3. Class & characteristics
Category of Measuring Point
4. MICs
Characteristics
5. Work Center
Unit of Measures
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

36 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF TASK


LIST MASTERS
1. Function Locations
Group Coding
2. Equipment Master
Counter
3. Class & characteristics
Planning Plant
4. MICs Maintenance Strategy
5. Work Center Work Center
6. Measuring Point Set of Operations
7. Task List Master MIs
8. Maintenance Item
9. Maintenance Plan

40 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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

1 XX GIL Plant Short Code:

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


2 X Discipline:

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


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

GB = Gear Box, BF= Bag Filter, BC = Belt Conveyor, AT = Analyzer, MO= DC Motor, etc
4 X Equipment Class Code Type( application) :

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


5 XX Type of Maintenance Task List:

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


= Inspection (attribute/Value EN-Environment;) J-Jishu Hozen ( General Inspection ) ZX-
Safety
Example: GCMGBHPM GCM-GBH-PM 1M Checks

GCEMODPM GCE-Motor-DC-PM 3M Checks

42 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 :--

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

43 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE STRATEGIES Continued..

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 | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE PACKAGE
Strategy GILDAY

Cycle Length UOM Maintenance Cycle Text Cycle Short Text


7 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

Strategy GILMON

Cycle Length UOM Maintenance Cycle Text Cycle Short Text


6 MON Half yearly 6M
12 MON Yearly 1Y
24 MON 2 Yearly 2Y
48 MON 5 Yearly 5Y

46 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE PACKAGE
Continued..
Strategy PERFHR

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

48 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF MAINTENANCE


ITEM MASTER

1. Functional Locations
Equipment /Function Location
2. Equipment Master
Master
3. Class & characteristics Task list Master
4. MICs Strategy
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

50 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


MAINTENANCE MASTERS

BASIC MASTERS BASIC CONTENTS OF MAINTENANCE


PLAN MASTER

1. Functional Locations
Maintenance Item Master
2. Equipment Master Strategy
3. Class & characteristics Scheduling parameter
4. MICs
5. Work Center
6. Measuring Point
7. Task List Master
8. Maintenance Item
9. Maintenance Plan

52 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


II. MANAGING MAINTENANCE PROCESSES

56 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE PROCESSES

BASIC PROCESSES BASIC STEPS OF MAINTENANCE


PROCESSES
1. Preventive Maintenance Creation of Notification
Creation of Orders
2. Break down Maintenance
Execution of Orders
3. Shut down Maintenance Confirmation of Orders
4. Condition base Maintenance Technical Confirmation of
5. Work shop Repair Orders
6. External Repair/Services Creation of Purchase Request
Creation of Purchase Orders
7. Calibration
Service Entry Sheets
Creation of Measuring Points
& Measuring Documents
Installation / De-installation of
Equipments
57 Presentation Title | Confidential | Document ID | Mar 15, 2017
1. PREVENTIVE MAINTENANCE PROCESS

BASIC PROCESSES

1. Preventive Maintenance BASIC STEPS OF PREVENTIVE


MAINTENANCE PROCESS
2. Break down Maintenance
Selection of Orders
3. Shut down Maintenance
Execution of Orders
4. Condition base Maintenance
5. Work shop Repair Confirmation of Orders

6. External Repair/Services Technical Completion of


7. Calibration Orders

58 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Selection of Order H/L TO ORDER TYPES

BASIC STEPS OF MAINTENANCE


Go to T. Code - IW39
PROCESSES
Selection of Orders Flag Outstanding & In process
check box
Execution of Orders
Enter Order Type PM01 Select from Drill Down
Confirmation of Orders
Technical Completion of Orders Enter Period ( Date from..to
)

Enter Status exclusive in CRTD, CNF ,


Multiple Selection TECO & CLSD

Enter Maintenance Plant

Enter Planner group for Order Select from Drill Down

Execute by clicking
button

Order list of relevant section


Appears

59 Presentation Title | Confidential | Document ID | Mar 15, 2017


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

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

60 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 MAT-
CAP

PM12 --- CIVIL MAINTENANCE ORDERS

All Work Orders raised for Civil Work E.g. Building/ Plumbing/ Carpentry/ Painting/
Foundation
64 etc are covered
Presentation under| this
Title | Confidential Order
Document Type
ID | Mar and MAT-CIV
15, 2017
MAINTENANCE ACTIVITY TYPES IN PM ORDERS

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

65 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Selection of Order H/L TO ORDER TYPES

BASIC STEPS OF MAINTENANCE


Go to T. Code - IW39
PROCESSES
Selection of Orders Flag Outstanding & In process
check box
Execution of Orders
Enter Order Type PM01 Select from Drill Down
Confirmation of Orders
Technical Completion of Orders Enter Period ( Date from..to
)

Enter Status exclusive in CRTD, CNF ,


Multiple Selection TECO & CLSD

Enter Maintenance Plant

Enter Planner group for Order Select from Drill Down

Execute by clicking
button

Order list of relevant section


Appears

66 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
BASIC STEPS OF MAINTENANCE
PROCESSES
Select desired order
Selection of Orders
Execution of Orders Move to SAP Screen
Confirmation of Orders
Technical Completion of Orders

67 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Execution of Orders
BASIC STEPS OF MAINTENANCE
Go to T. Code - IW32
PROCESSES
Selection of Orders
Enter number of Selected Order
Execution of Orders
Confirmation of Orders Order status will be
Release PM01 Type Selected changed to REL from
Technical Completion of Orders Order CRTD

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 | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS

Schedule Order by Clicking End date & time will


BASIC STEPS OF MAINTENANCE be changed by system
PROCESSES Determine cost by clicking
Selection of Orders
Execution of Orders Save the Order
Confirmation of Orders
Technical Completion of Orders Move to SAP Screen

69 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Confirmation of Order
BASIC STEPS OF MAINTENANCE
PROCESSES Go to T. Code IW44

Selection of Orders Select Header Menu


Execution of Orders Confirmation

Confirmation of Orders Select via operation list in


Confirmation Menu
Technical Completion of Orders
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 CRTD, CNF ,


Selection List TECO & CLSD

70 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Execute by clicking button
BASIC STEPS OF MAINTENANCE
PROCESSES All relevant Orders with
Selection of Orders Operations will be copied on
Execution of Orders main screen
Confirmation of Orders
Technical Completion of Orders 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 | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS

BASIC STEPS OF MAINTENANCE Enter Actual Duration


PROCESSES
Selection of Orders Enter Confirmation Text
Execution of Orders
System will calculate Actual
Confirmation of Orders Duration
Technical Completion of Orders
Save Confirmation by clicking

Move to SAP Screen

72 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Technical Completion of
Order
BASIC STEPS OF MAINTENANCE
PROCESSES Go to T. Code - IW32
Selection of Orders
Execution of Orders Selection of Order Screen
Confirmation of Orders appeared
Technical Completion of
Orders Flag In process check box

Enter Order Type PM01

Enter Period (Date fromto)

Enter Status exclusive in CRTD, REL ,


Multiple Selection TECO & CLSD

Enter Maintenance Plant

Enter Planner group for Order Select from Drill Down

Execute by clicking
button

73 Presentation Title | Confidential | Document ID | Mar 15, 2017


1. PREVENTIVE MAINTENANCE PROCESS
Order list of relevant section
Appears
BASIC STEPS OF MAINTENANCE
PROCESSES Select order and click
Selection of Orders
Execution of Orders Order Main Header Screen
Confirmation of Orders Opens
Technical Confirmation of
Click Settlement Rule button
Orders
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 | Mar 15, 2017
2. BREAKDOWN MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF BREAKDOWN


MAINTENANCE PROCESS
1. Preventive Maintenance Creation of M2-Notification
Selection of M2-Notification
2. Break down Maintenance
Creation of PM02-Order
3. Shut down Maintenance
Selection of Order
4. Condition base Maintenance Execution of Orders
5. Work shop Repair Confirmation of Orders
6. External Repair/Services Technical Completion of Orders
Execution & Completion of
7. Calibration
Notification
Why-Why Analysis

75 Presentation Title | Confidential | Document ID | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
Creation of M2 Notification Manual Process
BASIC STEPS OF
MAINTENANCE PROCESSES
Go to T. Code IW21Create
Creation of M2-Notification Notification
Selection of M2-Notification Select from Drill Down
Enter Notification Type
Creation of PM02-Order H/L TO N/F Types

Selection of Order Do not Enter Notification System Generated


Number
Execution of Orders
Confirmation of Orders
Notification Tab Screen Appears
Technical Completion of Orders
Execution & Completion of
Click Enter Button
Notification
Why-Why Analysis Enter Notification Description

Enter Equipment / FL /
Assembly (as required)

Enter Reported By (Name)

76 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


Notification Types

Notification Type Description Number Ranges From -To


M1 Maintenance Request 1000000000 to 1999999999
M2 Malfunction, B/Down 2000000000 to 2999999999
M3 UnsafeCond./Accident 3000000000 to 3999999999
M4 Abnormality Record 4000000000 to 4999999999
M5 Recommendation 5000000000 to 5999999999
M6 Work Request- W.Shop 6000000000 to 6999999999

81 Presentation Title | Confidential | Document ID | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
Creation of M2 Notification Manual Process
BASIC STEPS OF
MAINTENANCE PROCESSES
Go to T. Code IW21Create
Creation of M2-Notification Notification
Selection of M2-Notification Select from Drill Down
Enter Notification Type
Creation of PM02-Order H/L TO N/F Types

Selection of Order Do not Enter Notification System Generated


Number
Execution of Orders
Confirmation of Orders
Notification Tab Screen Appears
Technical Completion of Orders
Execution & Completion of
Click Enter Button
Notification
Why-Why Analysis Enter Notification Description

Enter Equipment / FL /
Assembly (as required)

Enter Reported By (Name)

82 Presentation Title | Confidential | Document ID | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
Popup Massage of warranty If equipment Under
BASIC STEPS OF warranty
Prompts
MAINTENANCE PROCESSES
Creation of M2-Notification Enter Code of STD TEXT
Attached
Selection of M2-Notification
Creation of PM02-Order Main Work center/ Planner All information Defaulted
Group etc Defaulted & can be from equipment master
Selection of Order Changed If Required
Execution of Orders
If Reqd Enter Long Text
Confirmation of Orders
Technical Completion of Orders
Go To Location Data Tab
Execution & Completion of
Notification Flag breakdown check box
Why-Why Analysis
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 | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
Selection of M2 Notification
BASIC STEPS OF
MAINTENANCE PROCESSES Go to T. Code IW28 Selection
of Notification
Creation of M2-Notification
Selection of M2-Notification Flag check box Outstanding or
In process (as Reqd)
Creation of PM02-Order
Selection of Order Enter Notification Date

Execution of Orders Enter Planner group


Confirmation of Orders Select from Drill Down

Technical Completion of Orders Enter Maintenance Plant

Execution & Completion of Click Enter Button


Notification
Why-Why Analysis 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 | Mar 15, 2017


Navigate. SAP Screen
2. BREAKDOWN MAINTENANCE PROCESS
Creation of PM02 Type Order
BASIC STEPS OF from Notification
MAINTENANCE PROCESSES
Creation of M2-Notification M2 Notification selected in
Changed Mode as explained in
Selection of M2-Notification pervious sheet
Creation of PM02-Order
Click Create button
Selection of Order
Execution of Orders of Order Tab

Confirmation of Orders Create Order Popup Screen


Technical Completion of Orders Appears with Defaulted data
from notification
Execution & Completion of
Enter PMActType BDM & click Select from Drill Down
Notification
continue button & save
Why-Why Analysis
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 | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF
MAINTENANCE PROCESSES Process of Selection of Order,
Creation of M2-Notification Execution of Order, confirmation
& TECO will be similar to processes
Selection of M2-Notification explained in process
Creation of PM02-Order 1. Preventive Maintenance

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 | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
Execution of M2 Notification
BASIC STEPS OF (Order not generated)
MAINTENANCE PROCESSES
Creation of M2-Notification M2 Notification selected in
Changed Mode as explained in
Selection of M2-Notification pervious Process
Creation of PM02-Order To Attach Std Text Go to Effect Select from Drill Down
Selection of Order field & select relevant code of
Std Text
Execution of Orders
Confirmation of Orders Insert Text popup screen
Technical Completion of Orders appears.

Execution & Completion of On Insert Text screen Flag Select from Drill Down
Notification Expand immediately , enter Text
ID ST & click on dropdown of
Why-Why Analysis 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 | Mar 15, 2017
2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF Next Popup screen Find SAP Select from Drill Down

MAINTENANCE PROCESSES script text will appear. Select


relevant text & click continue
Creation of M2-Notification button
Selection of M2-Notification
Creation of PM02-Order Now popup screen Insert Text
appear again with text attached.
Selection of Order Click Continue Button
Execution of Orders
Confirmation of Orders Desired Standard Text Get
Technical Completion of Orders copied in long text. Complete it
& go back to main screen
Execution & Completion of
Notification Select malfunction& downtime
tab and Enter down time end
Why-Why Analysis Date &Time.

Click Complete Flag and


complete Notification

Navigate> SAP Screen

88 Presentation Title | Confidential | Document ID | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF Create Why Why Analysis
MAINTENANCE PROCESSES Sheet

Creation of M2-Notification Go to T. Code -- ZRPM-WHY


Selection of M2-Notification
Creation of PM02-Order Enter Plant , Plant Section & Select from Drill Down
Planner group
Selection of Order
Execution of Orders Enter Date Range (From...To)
Confirmation of Orders
Select status by flagging and
Technical Completion of Orders execute
Execution & Completion of
Notification List of Notification appears (as
per selection criteria)
Why-Why Analysis
Select relevant notification &
double click it

Why Why Analysis screen


Appears

89 Presentation Title | Confidential | Document ID | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF Enter Object Code Select from Drill Down
MAINTENANCE PROCESSES
Enter Damage Code Select from Drill Down
Creation of M2-Notification
Selection of M2-Notification Enter all Possible Causes Select from Drill Down
Creation of PM02-Order (Possible reasons)
Selection of Order
Flag YES box to actual Cause
Execution of Orders
Confirmation of Orders Enter Observations
Technical Completion of Orders
Enter Analysis In Why Why
Execution & Completion of Field
Notification
Enter Rectification carried out
Why-Why Analysis
Enter Recommendations

Enter Responsible person and


Tar Date for Recommendations

Select Document Attached -


Say 2

90 Presentation Title | Confidential | Document ID | Mar 15, 2017


2. BREAKDOWN MAINTENANCE PROCESS
BASIC STEPS OF Next procedure of Standard text
shall be similar as explained in
MAINTENANCE PROCESSES
Process Execution of M2
Creation of M2-Notification Notification
Selection of M2-Notification
Click Complete Flag and
Creation of PM02-Order Complete Notification
Selection of Order
Save why-why Analysis
Execution of Orders
Confirmation of Orders Change Why Why Analysis
Technical Completion of Orders
Go to T. Code ZRPM_WHY
Execution & Completion of
Notification Go to Main screen of selected
Why-Why Analysis Notifications why why analysis

Click Put in Process Flag

Change Why Why analysis data


as per requirement

Save changed why-why


Navigate> SAP Screen Analysis

91 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF SHUTDOWN


MAINTENANCE PROCESS
1. Preventive Maintenance Creation of PM03 - Shutdown

2. Break down Maintenance Orders


Selection of PM03 - Shutdown
3. Shut down Maintenance
Orders
4. Condition base Maintenance Report of Shutdown Planning
5. Work shop Repair Creation of Direct Purchase
6. External Repair/Services Order
Creation of Direct Purchase
7. Calibration
Request (Indent)
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

92 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS

BASIC STEPS OF SHUTDOWN Creation of Shutdown Order


MAINTENANCE PROCESS
Creation of PM03 - Shutdown Go to T. Code IW31

Orders Enter Order Type - PM03 Select from Drill Down


Selection of PM03 - Shutdown
Enter Equipment Number By Drill Down go to
Orders selection screen
Report of Shutdown Planning Equipment selection screen
appears
Creation of Direct Purchase
Order Enter Equipment Class (Optional) Select from Drill Down
Creation of Direct Purchase
Equipment Category - M Select from Drill Down
Request (Indent)
Report of Shutdown Planning Maintenance Plant Select from Drill Down

Execution of Orders Enter plant Section Select from Drill Down


Confirmation of Orders
Enter Planner Group Select from Drill Down
Technical Completion of Orders
Click Execute Button

93 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
Select Desired Equipment &
BASIC STEPS OF SHUTDOWN click . Equipment entered in
MAINTENANCE PROCESS field
Creation of PM03 - Shutdown
Orders Enter Planning Plant & Enter Select from Drill Down

Selection of PM03 - Shutdown Create Shutdown


Orders Maintenance Order : Central
Header Screen appears
Report of Shutdown Planning
Creation of Direct Purchase Enter Order Description
Order
Go to Header data Tab & Enter
Creation of Direct Purchase PMActTYPE - SDM
Request (Indent) Go to Operation Tab and Enter
Execution of Orders Operations as required
Confirmation of Orders Enter Relevant Work Center Select from Drill Down

Technical Completion of Orders Enter Relevant Control key

Better to Create Separate Order


for PMIN & PMEX Control key
Pl Refer Next Slide

94 Presentation Title | Confidential | Document ID | Mar 15, 2017


PMIN PMEX
After Assigning Control Keys

Enter Work or Duration Select Operations

Enter WC Qty and Cal.Key Click on External Button

Popup screen External


Activity type Defaulted
Processing Operation appears

Select Operation & Go to Select Material Group ( S524 Select


Component TAB if Material For External Services) & Pur. from Drill
Required Group Down

Select Enter Vender , tracking No & Select


Enter required Material, qty, from Drill
from Drill click
S.Loc (see stock) & Batch Down
Down
External Processing operation
Again Go to Operation screen Select
from Drill
Appears
Enhancement Button and
enter Field key ZPM0001, Down
Go to service tab & Select Select
Position from Drill
Desired Services from Service
Master or write Description only Down
Click Gen Data Button & Get & Enter Required Quantity
Reservation Number on comp
detail screen & come back Enter Cost Element & Press
Enter

95 Presentation Title | Confidential | Document ID | Mar 15, 2017


Click scheduling & determine Enter Cost Element & Press
cost button Enter

Create Purchase Requisition


For Release Order Press Icon
screen appears. Enter Dept and
Press Enter
Save Order by click button
Repeat above three steps for
Navigate> SAP Screen Next Operation's

Go to Header Screen & Click


Determine cost button
You can
See PR No
Thru GEN For Release Order Press Icon
data->Act
data Tab
Save order by click button

Navigate> SAP Screen

96 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS
Creation of PM03 - Shutdown
Orders
Selection of PM03 -
Shutdown Orders Process of Selection of
Order, Execution of Order,
Report of Shutdown Planning
confirmation & TECO will be
Creation of Direct Purchase similar to processes
Order explained in process
Creation of Direct Purchase 1. Preventive Maintenance
Request (Indent)
Report of Shutdown Planning
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

97 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
Report1. of Shutdown
BASIC STEPS OF SHUTDOWN Planning
MAINTENANCE PROCESS
Go to T. Code IW49N
Creation of PM03 - Shutdown
Orders Display order & Operation:
selection of order & Operation
Selection of PM03 - Shutdown screen appears
Orders
Report of Shutdown Planning Flag Outstanding & In process
Order
Creation of Direct Purchase
Order Enter Order type Select from Drill Down

Creation of Direct Purchase


Enter Main work center Select from Drill Down
Request (Indent)
Execution of Orders Enter Period (dates)
Confirmation of Orders
Maintenance Plant Select from Drill Down
Technical Completion of Orders
Enter Plant Section Select from Drill Down

Enter Planner Group Select from Drill Down

98 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS

BASIC STEPS OF SHUTDOWN Click Execute Button


MAINTENANCE PROCESS
Creation of PM03 - Shutdown Report of Order with Operation
etc Appears
Orders
Selection of PM03 - Shutdown View Reports with Relevant
Layout selection
Orders
Report of Shutdown Planning Navigate> SAP Screen
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 | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
Report 2 of Shutdown
BASIC STEPS OF SHUTDOWN Planning (MATERIAL)
MAINTENANCE PROCESS
Creation of PM03 -Shutdown Go to IWBK Material
Availability Check (for orders)
Orders
Selection of PM03 -Shutdown Material availability Information
screen
Orders
Report of Shutdown Planning Click Multiple Selection of Order
Creation of Direct Purchase Field

Order Click Multiple selection button Select from Drill Down


Creation of Direct Purchase
Request (Indent) Flag outstanding & In process
Execution of Orders Enter Order Type- PM09
Confirmation of Orders
Technical Completion of Orders Enter Period (dates)

Maintenance Plant Select from Drill Down

Enter Plant Section Select from Drill Down

Enter Planner Group Select from Drill Down


100 Presentation Title | Confidential | Document ID | Mar 15, 2017
3. SHUTDOWN MAINTENANCE PROCESS
Click Execute Button
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS Report of Order with Operation
Creation of PM03 -Shutdown etc Appears
Orders
Go to back to Multiple selection
Selection of PM03 -Shutdown screen & Execute
Orders
Report of Shutdown Planning Paste Selected Orders &
execute
Creation of Direct Purchase
Order You will reach back to main
screen of Material availability
Creation of Direct Purchase Information
Request (Indent)
Execution of Orders Click execute button again

Confirmation of Orders Screen of Availability list of


Technical Completion of Orders Materials for Operations will
appears

On This Screen You Will Get


Order wise Materials with Stock
Navigate> SAP Screen
Availability status

101 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
Creation of Direct Purchase
BASIC STEPS OF SHUTDOWN Order (For Contractors)
MAINTENANCE PROCESS
Creation of PM03 -Shutdown Go to T. Code ME21N Create
Purchase Order
Orders
Selection of PM03 -Shutdown Select Type of Purchase Order Select from Drop Down

Orders
Enter Vendor Code Select from Drop Down
Report of Shutdown Planning thru Vendors : Purchasing

Creation of Direct Purchase Enter Purchase Organization,


Purchase Group & Company Select from Drop Down
Order (For Contractors) Code
Creation of Direct Purchase
Go to item overview Tab and
Request (Indent) Select from Drop Down
Enter Account Assignment K
Execution of Orders and Item category - D
Confirmation of Orders
Enter Short text of Services
Technical Completion of Orders
Enter Material Group , Plant , Select from Drop Down.
tracking number (Employee) Search Tracking number
and Department (planner group) thru Vendor by Company
code

102 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
BASIC STEPS OF SHUTDOWN
MAINTENANCE PROCESS Go to Item Tab and Enter Select from Drop Down
Services number , Qty
Creation of PM03 -Shutdown
Orders Go to Account Assignment Sub Select from Drop Down
Tab and Enter G/L Account
Selection of PM03 -Shutdown number and Cost center
Orders
Report of Shutdown Planning Check entries by Clicking
Button
Creation of Direct Purchase
Order (For Contractors) Correct Entries If error massage
other wise Save the order
Creation of Direct Purchase
Request (Indent) Navigate> SAP Screen
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

103 Presentation Title | Confidential | Document ID | Mar 15, 2017


4. CONDITION BASE MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF SHUTDOWN


MAINTENANCE PROCESS
1. Preventive Maintenance Creation of Measuring Point
Selection of Measuring Point
2. Break down Maintenance
Creation of Measuring Document &
3. Shut down Maintenance Auto Notification
4. Condition base Maintenance Creation of Entry List
Measuring Document Thru Entry list
5. Work shop Repair
Selection of M8 type Notification
6. External Repair/Services Creation of Corrective Maintenance
7. Calibration Order Thru Notification
Execution of Orders
Confirmation of Orders
Technical Completion of Orders

104 Presentation Title | Confidential | Document ID | Mar 15, 2017


3. SHUTDOWN MAINTENANCE PROCESS
Creation of Direct Purchase
BASIC STEPS OF SHUTDOWN
Requisition (For Spare)
MAINTENANCE PROCESS
Creation of PM03 -Shutdown Go to T. code ME51N -Create
Orders PR

Selection of PM03 -Shutdown Enter PR Type & Header note Select from Drop Down
Orders
Account Assignment Type U & Select from Drop Down
Report of Shutdown Planning Item Category leave Blank
Creation of Direct Purchase
Order (For Contractors) Enter Material & Reqd Qty Select from Drop Down

Creation of Direct Purchase Enter Del date , Plant &


Request (Indent) Tracking number (planner Select from Drop Down
group)
Execution of Orders
Confirmation of Orders Check entries by Clicking
Button
Technical Completion of Orders
Correct Entries If error massage
other wise Save the Purchase
request

Navigate> SAP Screen


105 Presentation Title | Confidential | Document ID | Mar 15, 2017
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITION Creation of Measuring Point
BASE MAINT. PROCESS
Go to T. Code - IK01 -Crete
Creation of Measuring Point
Measuring Point
Selection of Measuring Point
Creation of Measuring Select Measuring Point Object -
IEQ
Document & Auto notification
Creation of Entry List Select & enter Equipment
Measuring Document Thru number

Entry list Select Relevant Measuring


Selection of M8 type Point Category (Except L & F)
Notification Do not flag MP as counter for
Creation of Corrective CBM
Maintenance Order Thru
Click on Enter Button
Notification
Execution of Orders Write Measuring Position &
Confirmation of Orders Description
Technical Completion of
Orders

106 Presentation Title | Confidential | Document ID | Mar 15, 2017


4. CONDITION BASE MAINTENANCE PROCESS

BASIC STEPS OF CONDITION Enter relevant Characteristic


BASE MAINT. PROCESS (UOM & decimal Place
Creation of Measuring Point defaulted)

Selection of Measuring Point Go to Additional data Button


Creation of Measuring header tool bar
Document & Auto notification Enter Upper range limit & Lower
Creation of Entry List range limit
Measuring Document Thru
Click on Enter Button
Entry list
Selection of M8 type Main screen appears. Now click
on Save button to save MP
Notification
Creation of Corrective Navigate> SAP Screen
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

107 Presentation Title | Confidential | Document ID | Mar 15, 2017


4. CONDITION BASE MAINTENANCE PROCESS

BASIC STEPS OF CONDITION Selection of Measuring Point


BASE MAINT. PROCESS
Go to T. Code - IK07 Display
Creation of Measuring Point measuring Point : Measpoint
Selection of Measuring Point Selection
Creation of Measuring Enter Characteristics & MP
Document & Auto notification Category
Creation of Entry List
Click Execute Button
Measuring Document Thru
Measuring point list appears
Entry list
Selection of M8 type Notification Select relevant Measuring point
Creation of Corrective
Navigate> SAP Screen
Maintenance Order Thru
Notification
Execution of Orders
Confirmation of Orders
Technical Completion of
Orders

108 Presentation Title | Confidential | Document ID | Mar 15, 2017


4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITION Creation of Measuring
BASE MAINT. PROCESS Document
Creation of Measuring Point
Go to T. Code IK11 - Crete
Selection of Measuring Point
Measuring Document
Creation of Measuring
Document & Auto Notification Enter Measuring Point (as
selected)
Creation of Entry List
Measuring Document Thru Again Click on Enter Button
Entry list
Enter MeasRdg as taken from
Selection of M8 type Notification site
Creation of Corrective
Again Click on Enter Button
Maintenance Order Thru
Notification A Massage Appears In case
Execution of Orders Reading is Outside range
Confirmation of Orders
Technical Completion of Again Click on Enter Button
Orders
Main screen of M8 type
Notification Generates
Automatically
109 Presentation Title | Confidential | Document ID | Mar 15, 2017
4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITION Enter Reported by & click Enter
BASE MAINT. PROCESS button
Creation of Measuring Point
An Auto Notification of M8 type
Selection of Measuring Point Created
Creation of Measuring
A massage comes for
Document & Auto Notification Measuring document Created
Creation of Entry List
Navigate> SAP Screen
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 | Mar 15, 2017


4. CONDITION BASE MAINTENANCE PROCESS
BASIC STEPS OF CONDITION Creation of Entry List
BASE MAINT. PROCESS
Go to T. Code IK31 -
Creation of Measuring Point Measuring reading entry list:
Selection of Measuring Point Create
Creation of Measuring Click on Enter Button
Document & Auto notification Screen of Measuring reading
Creation of Entry List entry list: Create Appears
Measuring Document Thru Enter entry list name &
Entry list Description
Selection of M8 type Enter measuring point numbers
Notification As selected from drop down list
Creation of Corrective Click on Enter Button
Maintenance Order Thru All details of Measuring points
Notification Appears in list
Execution of Orders
Now Click on Save Button
Confirmation of Orders
Technical Completion of A Massage measurement
Orders reading entry list xxx saved.

Navigate> SAP Screen


111 Presentation Title | Confidential | Document ID | Mar 15, 2017
4. CONDITION BASE MAINTENANCE PROCESS
Creation of Measuring
BASIC STEPS OF CONDITION Document Thru Entry list
BASE MAINT. PROCESS
Go to T. Code IK34
Creation of Measuring Point Collective entry of
Selection of Measuring Point MeasDocuments: Initial screen
Creation of Measuring Enter Entry list number
Document & Auto notification
Click on Enter Button
Creation of Entry List
Measuring Document Thru Collective entry of
MeasDocuments: overview
Entry list screen Appears
Selection of M8 type
Enter measuring Reading in
Notification relevant measuring point field
Creation of Corrective
Click on Enter Button
Maintenance Order Thru
Notification A Massage Appears In case
Execution of Orders Reading is Outside range &click
Confirmation of Orders again enter button. M8
Technical Completion of Notification will generate
Orders A massage appears as xx Navigate>
Measuring document Created SAP Screen
112 Presentation Title | Confidential | Document ID | Mar 15, 2017
5. REPAIR MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF REPAIR


MAINTENANCE PROCESS
1. Preventive Maintenance Creation of M6-Notification
Selection of M6-Notification
2. Break down Maintenance
Creation of PM09-Order
3. Shut down Maintenance
Selection of Order
4. Condition base Maintenance Execution of Orders
5. Work shop Repair Confirmation of Orders
6. External Repair/Services Technical Completion of Orders
Execution & Completion of
7. Calibration
Notification

113 Presentation Title | Confidential | Document ID | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
Creation of M6 Notification Manual Process
BASIC STEPS OF
MAINTENANCE PROCESSES Go to T. Code IW21Create
Creation of M 6-Notification Notification
Selection of M 6-Notification Enter Notification Type Select from Drill Down
Creation of PM09-Order H/L TO N/F Types

Selection of Order Do not Enter Notification


Number System Generated
Execution of Orders
Confirmation of Orders Click Enter Button
Technical Completion of Orders
Execution & Completion of Notification Tab Screen Appears
Notification
Enter Notification Description

Enter Equipment / FL /
Assembly (as required)

Enter Reported By (Name)

Enter Code of STD TEXT Select from Drill Down


Attached as per requirement

114 Presentation Title | Confidential | Document ID | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF Main Work center/ Planner All information Defaulted
MAINTENANCE PROCESSES Group etc Defaulted & can be from equipment master

Creation of M2-Notification Changed If Required

Selection of M2-Notification
Write Details of Job in Long Text
Creation of PM02-Order
Selection of Order Go To Location Data Tab
Execution of Orders
Confirmation of Orders Save the Notification
Technical Completion of Orders
Execution & Completion of Navigate> SAP Screen

Notification
Why-Why Analysis

115 Presentation Title | Confidential | Document ID | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF Selection of M6 Notification
MAINTENANCE PROCESSES
Creation of M6-Notification Go to T. Code IW28 Selection
of Notification
Selection of M6-Notification
Creation of PM09-Order Flag check box Outstanding (as
reqd)
Selection of Order
Execution of Orders Enter Notification Date
Confirmation of Orders
Select Notification & Create
Technical Completion of Orders
PM09 Type Order
Execution & Completion of
Notification Click Create button

of Order Tab

Navigate> SAP Screen

116 Presentation Title | Confidential | Document ID | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
Create PM09 Type Order
BASIC STEPS OF
MAINTENANCE PROCESSES Select Relevant Maintenance Select from Drill Down
Creation of M6-Notification Activity Type( Always RVN)
Selection of M6-Notification
Go to Operation TAB
Creation of PM09-Order
Selection of Order Select Relevant Work Center Select from Drill Down

Execution of Orders (Type 0001)

Confirmation of Orders Enter Number of Hours


Technical Completion of Orders
Execution & Completion of Other Field automatically
Populated.
Notification
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 | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF
MAINTENANCE PROCESSES
Creation of M6-Notification
GO to IW38 & Search PM09
Selection of M6-Notification Type Order
Creation of PM09-Order
Navigate> SAP Screen
Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

118 Presentation Title | Confidential | Document ID | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF Release Order & Issue Required
MAINTENANCE PROCESSES Material.
Creation of M6-Notification
Carry out Repair Work As per
Selection of M6-Notification Request
Creation of PM09-Order
Selection of Order Navigate> SAP Screen
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

119 Presentation Title | Confidential | Document ID | Mar 15, 2017


5. REPAIR MAINTENANCE PROCESS
BASIC STEPS OF
Further process of order will
MAINTENANCE PROCESSES
remain same as explained in
Creation of M6-Notification process 1. Preventive
Selection of M6-Notification Maintenance

Creation of PM09-Order Navigate> SAP Screen


Selection of Order
Execution of Orders
Confirmation of Orders
Technical Completion of Orders
Execution & Completion of
Notification

120 Presentation Title | Confidential | Document ID | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS

BASIC PROCESSES BASIC STEPS OF EXTERNAL REPAIR


MAINTENANCE PROCESS

1. Preventive Maintenance Creation of PM09 Type Order


Selection PMEX Activity type
2. Break down Maintenance
Creation of Purchase
3. Shut down Maintenance Requisition
4. Condition base Maintenance Creation Of Purchase Order
5. Work shop Repair Confirmation of External Service
Entry Sheet
6. External Repair/Services
Technical Completion of Orders
7. Calibration

121 Presentation Title | Confidential | Document ID | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF EXTERNAL Creation of PM09 Type Repair
REPAIR PROCESSES Order

Select Relevant Type Select from Drill Down


Creation of PM09 Type Order Maintenance Activity (Always
RVN, RWN)
Selection PMEX Activity type
Go to Operation TAB
Creation of Purchase Requisition
Select Control Key As PMEX
Creation of Purchase Order
Enter Operation & Select It
Confirmation of External Service
Entry Sheet Click External Service Button

Technical Completion of Orders POP Screen Will Appear Enter Select from Drill Down
Material Group S 524,Purchase
Group, Tracking Number

Enter & GO to External


Processing operation Screen

122 Presentation Title | Confidential | Document ID | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF Write Short Text of External
MAINTENANCE PROCESSES Service , Approximate Cost of
Repair, Quantity & Unit
Creation of PM09 Type Order
Selection PMEX Activity type Write Desired Vendor Code
Creation of Purchase
Enter Cost Element & click Select from Drill Down
Requisition
Creation of Purchase Order Pop Screen of Purchase Select from Drill Down
Confirmation of External Service request Will Appear Enter
Entry Sheet Department (i.e Main Planner
Technical Completion of Orders group)

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 | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF
MAINTENANCE PROCESSES Go To Change Mode of PR
(ME52N)
Creation of PM09 Type Order
GO To Document Overview &
Selection PMEX Activity type
Select Relevant PR
Creation of Purchase
Requisition GO TO Customer TAB & Enter
Creation of Purchase Order all Required Deatils
Confirmation of External
Service Entry Sheet Save PR
Technical Completion of
Orders Navigate> SAP Screen

124 Presentation Title | Confidential | Document ID | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF
MAINTENANCE PROCESSES MM Will Prepare Purchase Order
on PR
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 | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF
MAINTENANCE PROCESSES
MM Will Prepare Service Entry Sheet
Creation of PM09 Type Order You will Accept Service Entry Sheet

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 | Mar 15, 2017


6. EXTERNAL REPAIR MAINTENANCE PROCESS
BASIC STEPS OF This Type of Order to be TECO
MAINTENANCE PROCESSES only When FINAL Service Sheet
Made.
Creation of PM09 Type Order
Save
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 | Mar 15, 2017


III. MANAGING REPORTS

128 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


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 | Mar 15, 2017


6.2 LIST OF DEVELOPED REPORTS

139 Presentation Title | Confidential | Document ID | Mar 15, 2017


LIST OF DEVELOPED REPORTS:

S. The
No. following
PLANT REPORTS
are the Reports that are being developed in SAP:
1 List of Damage & Cause - Summary Report (Equipment wise)

2 Breakdown Matrix - Equipment ABC indicator & breakdown category wise

3 Work Center / Equipment wise Material Consumption

4 Equipment Schedule Maintenance Report

5 Breakdown why-why Analysis Report


6 PM order Skipped / Rescheduled Report

7 PM Order Slippage Summary Report ( Schedule Maintenance Slippage in


Plant VC)
8 Preventive Maintenance Work Request Report
9 Motor Failure Report
10 Inspection Check List

140 Presentation Title | Confidential | Document ID | Mar 15, 2017


LIST OF DEVELOPED REPORTS:

S. No. 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)

141 Presentation Title | Confidential | Document ID | Mar 15, 2017


LIST OF DEVELOPED REPORTS:

S.No. 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

142 Presentation Title | Confidential | Document ID | Mar 15, 2017


143 Presentation Title | Confidential | Document ID | Mar 15, 2017
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 from Drop Down


Select Relevant Measuring Point Category

Flag for Measuring Point as a Counter

Write Measuring Position Description

Write Description of Measuring Point

Select From Drop


Attach Relevant CHARACTERISTICS Down ,Always use
RUNNINGHOURS

144 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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

Always Select Category


L- for Lubrication &
Select Relevant Measuring Point Category F- Fuel Consumption

Flag for Measuring Point as a Counter

Write Measuring Position Description

Write Description of Measuring Point

Select From Drop


Attach Relevant CHARACTERISTICS Down , ,Always LUB
CONCOSUMPTION..

146 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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 from Drop Down


Select Relevant Measuring Point Category

Press Icon

Write Measuring Position Description

Write Description of Measuring Point

Select From Drop


Attach Relevant CHARACTERISTICS Down

148 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


CREATION OF MESURING POINT DOCUMENT (IK11)

Creation of Measuring Document IK11

Select Desired Measuring Point Select from Drop Down

Enter ICON Button Next Screen will Appear


for entering Reading

Counter should be
GREATER than
Enter Counter Reading or Difference of Counter Previous Reading or
Difference not more
than 24 Hours
Press ICON Button For Save

Message : Measuring Document ..Created.

THE END

150 Presentation Title | Confidential | Document ID | Mar 15, 2017


MAINTENANCE ITEM Continued..

WITH
TIME BASED PACKAGE

151 Presentation Title | Confidential | Document ID | Mar 15, 2017


CREATE MAINTENANCE ITEM(TIME BASE)1/1 IP04

Create Maintenance Item IP04

Select from Drop Down


Maintenance Plan Category

Maintenance Strategy 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

Select from Drop Down


Maintenance Activity Type
(Use PVM Or AMC )

Attach Relevant Task List

152 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 , Screen will appear with List of Task


Lists

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 | Mar 15, 2017


MAINTENANCE ITEM

WITH
PERFORMANCE BASED PACKAGE

154 Presentation Title | Confidential | Document ID | Mar 15, 2017


CREATE MAINTENANCE ITEM (PERFORMANCE BASE) 1/2

Create Maintenance Item IP04

Maintenance Plan Category Select from Drop Down

ALWAYS Use PERFHR


Maintenance Strategy For Plant,TPP,DG
Equipment & MINHR
For Mines Equipment
Write Maintenance Item Description

Select from Drop Down


Enter Equipment

Write ORDER Type This will be PM01


Always

Select from Drop Down


Maintenance Activity Type

Attach Relevant Task List

155 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017
NAVIGATE > SAP SCREEN

Creation of Maintenance Item-[IP04]

157 Presentation Title | Confidential | Document ID | Mar 15, 2017


CREATION OF MAINTENANCE PLAN (TIME BASE) Sheet 1/3 IP01

Create Maintenance Plan (IP01)

Maintenance Plan Number is System Generated


Number

Maintenance Category

Select from Drop


Maintenance Strategy Down ,Always Use
GILDAY & GILMON

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 | Mar 15, 2017
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 Fro Completion Requirement

159 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017


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

Create Maintenance Plan (IP01)

Maintenance Plan Number is System Generated


Number

Maintenance Category
Select from Drop
Down ,Always Select
PERFHR For Plant,
Maintenance Strategy
DG, TPP & MINHR
For Mines

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 | Mar 15, 2017
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 For Completion Requirement

162 Presentation Title | Confidential | Document ID | Mar 15, 2017


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 | Mar 15, 2017