Plant Maintenance Key User Presentation

SAP - An E.R.P. Package

Contents of PM Module

Benefits of PM Implementation

ERP OverviewERP Overview

What is an ‘E.R.P.’ ?

Why ‘E.R.P.’ is needed ?

Who are Global ‘E.R.P.’ Vendors?

What is ‘SAP’ ?

What is ‘Client Server’ Technology ?

General QuestionsGeneral Questions

E.R.P. : ENTERPRISE RESOURCE PLANNINGFor managing 4M’s of enterprise EFFECTIVELY.EFFECTIVELY.

MATERIAL MATERIAL

MACHINE MACHINE

MEN MEN

MONEY MONEY

What is an ERP?What is an ERP?

A Standard Software Package taking care of all

the needs of an enterprise.

‘E.R.P.’ integrates business processes across

the whole company.

‘E.R.P.’ provides & helps the enterprise to

adopt latest technology & international

business practices with minimum ease.

Why ERP?Why ERP?

Examples of Vendors Providing ERP Packages

SAP BAAN JD-Edwards Marshall People-soft

ERP VendorsERP Vendors

Systems, Applications, Products in Systems, Applications, Products in Data ProcessingData Processing

Walldroff, Germany.

SAP Stands for? SAP Stands for?

R/3R/3Client / ServerClient / Server

COCO

AMAM

PSPSWFWF

ISIS

MMMM

HRHR

SDSD

PMPM

PPPP

QMQM

FIFI

Integration Of PMIntegration Of PM

Overview Plant Maintenance Features of SAP PM Master Data Preparation Plant Maintenance Business Process Report Requirement Critical Success Factors

OutlineOutline

Overview Of Plant Maintenance

Definition: Maintenance is an action required to preserve or to retain the health of equipment.

Importance: Because of the increase in automation and the resulting high fixed costs of operational systems, plant maintenance plays a decisive role in the success of any business. Production system need to be available 24 hours a day in order to guarantee cost effective distribution of fixed cost

Plant Maintenance Plant Maintenance

Materials Management Finance / CostingMaterial master Accounting Service master Order settlementEquipment Bill of material Cost centerSpare parts planning Activity pricingInventory management Purchase of materials Services and contracts

Quality Management Asset ManagementInspection of parts Equipment and Asset linkCalibration

Production Planning Human ResourcePRT Scheduling Man Power Capturing

Plant Maintenance IntegrationPlant Maintenance Integration

The operational systems are managed using functional locations, equipment & sub-equipment.

Preventive maintenance and inspection plans which are done at a regular interval are released at a scheduled point of time.

Malfunctions and other direct requirements are entered directly as maintenance notification and forwarded to the respective workshop responsible for processing.

Maintenance tasks are carried out using maintenance orders.

Cost captured in the maintenance order is settled against the respective production cost center.

The completed maintenance notifications & orders form the basis for creating maintenance history.

Plant SupportPlant Support

Malfunction, RequestActivity

Malfunction, RequestActivity

Maintenance notificationwhatwhen wheretechnical infobreakdown

Order creationPlanning of task

whowhen, how longwhich stepsaccount assignment resources

Executionwithdrawalutilitiesprocurementwork steps

Technical informationmalfunctioncausesobjects affectedactivity

Maintenance history

Completion

Taskrequested

1111

Order

Confirmation

Closing

22223333 4444

5555

66667777

8888

Operation Maintenance planning Maintenance workshop

Fundamental Maintenance Processing StepsFundamental Maintenance Processing Steps

Master Data Preparation

MASTER DATA

MAINTENANCE PLANNING

NOTIFICATION PROCESSING

PM ORDER PROCESSING ( RUSH / UNPLANNED )

ORDER SETTLEMENT

PM PROCUREMENT & SPARES MONITORING

HISTORY & ANALYSES

ContentsContents

Master Data

Functional Location Equipment Catalog Profile (Object, Cause & Damage) Check List (Task List) & Plan Equipment Sub-Equipment Relation Equipment BOM Measuring Points & Counters Process Instruments for Calibration

Master Data ProcessingMaster Data Processing

Technical Object Management Functional location Equipment master data Permits Partner & Addresses Object link master data

Bill Of Material Location specific BOM. Equipment BOM. Assembly / Material BOM.

Master RecordsMaster Records

PM Work-Center.

PM Task-List -> Service sheet Functional location Equipment General

Measurement Point & Counter

PM Catalogues.

PM Material Master

External Service

Master Records Contd..Master Records Contd..

A functional location is an element in a technical structure, representing an area of a Plant at which Equipment/s can be installed.

Advantages of structuring functional location

1. Identifying the locations via codification logic.2. Relationship of Functional Location with Orgnization3. Identifying the hierarchical position in structure4. Generating the reports.

Functional LocationFunctional Location

Multilingual textsInternal note

Equipment usageClassification

DocumentsPartner/AddressesMeasuring points

Permits

Equipment master record

PM dataLocation data

Production resources/tools dataSerial number data

General Data

Equipment MasterEquipment Master

Advantages of BOM

MATERIALS PLANNING

MATERIAL/SPARES PLANNING

LOCATING MALFUNCTIONS

Work CentersWork Centers

It defines the group of workmen's or single person or machine or multiple machines responsible for carrying out the activity. This also indicates who is supposed to carry out the maintenance. It can be even machines.

PLANT MAINT. HISTORY

PM Order

•Costs•Materials•Operations

Equipment Plant Area(Functional location)

Notification

MAINTENANCE HISTORY

Notification historyOrder historyUsage list (Instll.Period)

Master Records•Description of Notif.•Time data,B/D Hrs.•Machine/ Object data•Fault location,Damage•Causes, Action taken

•Text,Object

PM Business Process

Preventive Maintenance (Time / Performance Based)

Breakdown MaintenanceMaintenance Request / ActivityRefurbishmentCalibration of process instrumentsCapital Investments

Key Business ScenarioKey Business Scenario

Scheduled Maintenance

Unscheduled Maintenance

Maintenance Plan

SchedulePlan

Create PM Orders

Adjust planned dates if requ’d

Maintenance Notification

Manually create orders

Short term planning in order

Release order

Execute maintenance

Maint operation completion confirmation

Technically complete order

Record technical data in notification

Complete notification

Settlement

Functional Flow SummaryFunctional Flow Summary

NotificationNotification

OrderOrder

ControlControl

ProcessingProcessing

CompletionCompletion

History Material usage, orders, notifications, PMIS, usage list

History Material usage, orders, notifications, PMIS, usage list

• Technical Object• Description

• Date• Malfunction

•Tasks to perform• Resources int./ext.

• Components• Tools

• Availability check• Release order• Print papers

• Material withdrawal planned/unplanned• External procurement

•Time confirmation•Techn.completion

• Order settlement• Techn. confirmation

44

55

22

33

11

Steps In PM ProcessingSteps In PM Processing

Purchaserequisition

Completionconfirmation

Maintenance orderMaintenance order

Op. 10: Internal processing

Op. 20: External processing

Service confirmationGoods receipt

Invoice receipt

Purchase order

Activity costs

Activity costs

Material Consumption

External Processing FlowExternal Processing Flow

Creation ofservice

specifications

Determinationof requirements

Serviceacceptance

Invoiceverification

Serviceentry

POmonitoring

Orderingprocess

Vendorselection

Quotationentry

Bid invitation

- User department- PM Plant maintenance- PS Project system

PO Invoice

?=

RFQ

Procurement StepsProcurement Steps

Maintenance orderMaintenance order

Internal Processing

operation 10: ME 3 hoursoperation 20: EL 1 hour

External processing

operation 30: EXT 1 hour

Material

2 pcs. Material ABC

Costs

Internal Processing: Rs 500.00

External Processing: Rs150.00

Material: Rs300.00

Total: Rs950.00

Costs

Internal Processing: Rs 500.00

External Processing: Rs150.00

Material: Rs300.00

Total: Rs950.00

Cost ProcessingCost Processing

Plant wise viewMaintenance Group wise viewPlanner Group wise viewEquipment wise viewFunctional Location wise viewFinancial Period wise viewPlan vs Actual cost

Cost AnalysisCost Analysis

TYPES OF PM PLANNING

2) Counter based maintenanceA - With maintenance strategyB - With multiple counter plan

1) Time based planningMonthMonth

P1 x xP1 x xP2 x x x x x x xP2 x x x x x x x

kilometerkilometerP1 x xP1 x xP2 x x P2 x x

PM Reports

List of Breakdown Notifications( Daily & Monthly)

Equipment Breakdown HistoryMTTR / MTBR / MTBFDamage AnalysisManufacturer wise Breakdown Analysis

Break Down ReportBreak Down Report

Preventive maintenance schedulePreventive maintenance Performance

summaryPreventive maintenance feed back

summary(check list)Graphical Scheduling OverviewMaterial where used ListCost Analysis

Preventive Maintenance ReportPreventive Maintenance Report

Planned (Preventive )Maintenance Cost

Un-Planned (Breakdown) Maintenance

Maintenance Cost ReportMaintenance Cost Report

Goods Receipt Goods IssueSpare consumption through

Maintenance Order(261 Mov. type)Consumption through direct issue to

cost center(201 Mov. type)Consumption actual vs. planned budget

Material where used List

Spare Parts ReportSpare Parts Report

Cost at Work Center level

Cost of Internal Activity, External Services & Spares

Actual Cost Vs Planned Budget at work center level

Repairs & Maintenance BudgetRepairs & Maintenance Budget

Condition of a particular Equipment/Functional Location can be managed by Condition Based Monitoring by using Measuring Points & Counters which is created against Equipment/Functional Location (Trend Analysis), Characteristic Vs Time

The Preventive Maintenance (Internal / External) schedule can be generated with the help of counters ,In case of External Processing Purchase Requisitions are generated.

Condition Monitoring ReportCondition Monitoring Report

THANK YOU