pm process diagram 1

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Plant MaintenanceLevel-II Training

ByDhananjay Kedari


High Level Business Processes


Preventive Maintenance ( In-House)

Create Maintenance planCreate Maintenance plan

Create order from notification listCreate order from notification list

Notification Completion

Cause Damage Activity



History

Material usage, orders, notifications, PM-IS, usage list

History


Maintenance Order (Operations , Material, Labour, Tools Plannin

Order Scheduling

Order Confirmation

Good movement Time confirmation

Order Completion

Order settlement Technical completion

Schedule Maintenance Plan

Call Object (Notification / Order)List of NotificationList of NotificationNotification

Order

Maintenance order released to shop floorMaintenance order released to shop floor

Order ExecutionOrder Execution


Preventive/ Predictive Maintenance ( AMC with External Agency)

Create a settlement order for referenceobjectCreate a settlement order for referenceobject

Create a framework order (MM)

Vendor Value limit

Create a framework order (MM)

Vendor Value limit

History


History


Service Entry Sheet

Service entry sheet is updated for Purchase order

Service entry sheet acceptance/Order Completion


Schedule Maintenance PlanCreate a Maintenance plan

G/L account Service specification

Create a Maintenance plan

G/L account Service specification

Execution by vendorExecution by vendor

Purchase order

(Service entry sheet)

Purchase order



Breakdown Maintenance ( In-House)Notification

Technical object Date

Details Malfunction

Notification

Technical object Date

Details Malfunction

Order Creation and PlanningOrder Creation and Planning

Maintenance order released to shop floorMaintenance order released to shop floor

Order ExecutionOrder Execution





History


History


Maintenance Order

Operations Material

Internal/external resources Tools

Order Scheduling

Order release Capacity leveling

Shop Papers Availability check

Order Confirmation

Good movement Time & activity confirmation

Order Completion


User / ProductionUser / Production

Maintenance Planner

Maintenance Planner

Maintenance Planner

Maintenance Planner

Maintenance Work Center

Maintenance Work Center

Maintenance Planner

Maintenance Planner


Breakdown Maintenance ( External Agency)

Purchase

Requisition

Completion

Confirmation

Maintenance orderMaintenance order

Op. 10: Internal processing

Op. 20: External processing

Service confirmation

Goods receipt

Purchase order


Actual costs

Actual costs


Equipment Sent Out for repairsSAP R/3

Create/Process Order

Plan and Schedule Order

Put Order in Process

Post Material Movements

Post External Services

Confirm Time

Settle and Complete Order

Perform Evaluations in Plant Maintenance Information System

[PMIS]

Step Process steps System Agency

1

Create refurbishment order: After viable quantity of defective

materials gets collected from the shops, which were received,

into stores with damaged valuation type, a refurbishment order

has to be created.

SAPMaintenance /

reconditioning dept.

2

Process the Order: Required Operations are planned in the

order. Materials to be refurbished are issued to the order in

damaged valuation type. Spares / materials required for

refurbishment activity are requested through order.

SAPMaintenance /


3Purchase requisition for external refurbishment has to be

generated from order.SAP

Maintenance /


4

Purchasing Document refurbishment: After the selection of

vendor, if it is a one-time requirement purchase order is created.

If it is a long-term/repeated requirement, scheduling lines are

created from an existing scheduling agreement or purchase

order is created from an existing contract.

SAP Purchasing

5 Goods receipt at stores: for incoming refurbished material. SAP Stores

6Payment for refurbishment: Payment is made to the vendor for

the services delivered SAPFinance

7Complete the order: The maintenance confirms the job

completion by closing the order for time & work confirmation.SAP

Maintenance /


8

Goods receipt at stores: Refurbished goods are received into

stored with refurbished valuation type. SAP Stores

9

Financial treatment for the order: Refurbishment order is settled

using cost elements. Moving average price of refurbished

valuation type is changed due to order settlement.SAP Costing


Auto generation Service PR through maintenance order

If AMC/ ARC is existing

Purchase Dept make enquiry & create PO

Contract /FO reference to be mention in PR

Print/make Dispatch Advice

Make Excise Chalan if necessary

Send goods to vendor for rerepairs

rerepairs repairing

Receive the repaired goods

Are spares required for repair?

Create PR & PO for regularizing material purchase

PM user will create & accept service entry sheet

Creation of Maintenance order

Store will make GR based vendors bill


Create Maintenance Plan

Create Task List with Inspection Characteristics

Purchase order to the vendor

Planning the services & Service PR generation

Trigger PM Order through Deadline Monitoring /

manual

Inspection Lot generated automatically

Service entry sheet creation after calibration

Result Recording for Inspection Lot

Business Completion of Order

Send Out material & receive cal.

Equipment Calibration by External Agency


In House Equipment Calibration


Create Task List

Confirm Actual Time for Operations

Enter Usage Decision


Creation measurement document for results

Trigger PM Order through Deadline Monitoring/ manual

Release order & execute job


External Certification Services


Create Task List with Inspection Characteristics

Confirm Actual Time for Operations

Service entry sheet approval Technical Completion of Order

Purchase order creation

Trigger PM Order through Deadline Monitoring

Hiring of external agency by creating PR



THANK YOU!!

pm process diagram 1

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