1. Purpose: This document highlights the usage of Inspection Rounds functionality available within SAP PM in ECC 6.0 EHP 4 (current version in our business) which is enhanced through usage of Operation Account Assignment functionality that has been provided in ECC 6.0 EHP 5 (version to which we are upgrading).

2. Source system: The processes highlighted in this document are based on Prototypes designed in SAP SAN 100 (Sandbox) environment which has been upgraded to ECC 6.0 EHP 5.0 version during the first phase of our Upgrade.

3. Inclusion: Usage of Inspection Rounds and Operation Account Assignment functionality has been detailed in this document.

4. Exclusions:

These Functionalities are configurable within standard SAP with allowances for enhancements for any custom development. This document however only details the standard portions of the Functionalities which are sufficient for most Maintenance departments and are being used widely across Asset Maintenance intensive businesses.

Only Order type PM01 (System Generated Order in our case) in combination with Plant 0010 has been considered in the Prototype. All other Order Types and Plants have been untouched.

Please note that Inspections rounds/Operation account assignment can also be setup for Manually created Maintenance Orders if required. Usually Inspection rounds go well with Planned regular work. That is the reason that in current prototype PM01 Order Type (which is used for Planned Maintenance work in our business) has been used.

5. Terminologies and Process:

Inspection rounds: An Inspection Round collects similar repetitive activities and inspections on many different Technical objects.

Some of the characteristics that qualify for above in Maintenance of Physical Assets include:

- Repetitive activities such as Lubrication, Taking regular meter reads on measurement points etc.

- Activities that are planned based on time (such as Once a week, per day, per shift, and so on)

- A single Route is performed within the period defined above (say per day, per shift etc.)

- The total time of a route consists of Labour, Resources (Material/PRTs) and Travel through a set of Objects (for example, walking through a Plant/Plant section and inspecting all <or> a set of related Equipments in the plant/section, say all Rotables)

- The work is performed on different Technical objects, the number of objects can vary in terms of sequence and number dependant on time intervals

- Result of a route could be a follow up activity (i.e updating work order, notification etc.)

The Best Feature of Inspection Rounds functionality within SAP is that in a Single Maintenance Order, each activity (Operation) can be assigned to a different piece of Reference Object unlike Header assigned Orders that are currently used in our business with Header Reference Objects (Functional Locations/Equipments).

The reference objects that can be assigned to each Operation of Order (= activities of a Route) include:

- Functional Location- Equipments/ or Material + Serial No. (if Equipment Serialization is used)- Assembly- Measuring points- Free text items

There are 3 major stages of an Inspection Round, as below, which will be detailed in further sections:

1. Defining an Inspection Round2. Planning an Inspection Round3. Executing and Inspection Round

Operation Account Assignment: This is one of the most prominent new feature within SAP Plant Maintenance module in ECC 6.0, EHP 5 version to which we are upgrading.

This function allows you to use the Operation of a Plant Maintenance Order as an Account Assignment Object. This means:

- Order costs can now be posted to Order Cost table at operation level (new table PMCO_OP) as against current Order costs being posted to Order overall/header cost table (PMCO). This is based on a configuration setting to be done which is mentioned in next section

- Based on above, Order costs can now be Traced and Reported at individual Operation level <and if >used in conjunction with Inspection Rounds this would mean using a single Maintenance Order, you can post and report costs at each operation level, which may each be associated to a different Technical object – Equipments/Functional Locations, which was not possible while using Header account assignment concept (as used now)

- Account assignment i.e assignments of Cost centre/WBS etc are now possible at Order Operation Level. This naturally supplements Inspection Rounds functionality in which each Operation can be assigned to different Reference Technical objects

(Functional Locations, Equipments) and it is quite possible that every object or some objects are associated with different Cost centres/WBS etc.

- Settlement rules can now be defined at the level of individual Operations

- Multiple standard reports available to provide a detailed level of Operational Level Costing with many other details at Operation level.

6. Background pre-requisites and Configurations

1. Business Function set activated using SWF5 transaction in SAN (on ECC 6.0, EHP 5), to activate above functionalities include:

LOG_EAM_CI_3 - Enterprise Asset Management: Continuous Improvements – For Inspection Rounds functionality

LOG_EAM_OLC – Operation Account Assignment

2. Configurations pertaining to

Inspection Round

a. Define Notification and Order Integration

IMG --> PM & CS --> Maintenance & Service Processing -> Maintenance & Service Orders --> Functions & Settings for Order types -> Define Notification and Order Integration

No changes done to existing configuration as the pre-requisites were satisfied as per current configuration.

As per pre-requisite, against PM Order PM01, Enh. Object List set as “Assignment of Operations to Object List entries inactive”

b. Configuring Maintenance Plan Category (OPTIONAL)

Configured a Maintenance Plan category “IR” in SAN to keep the process distinct. Configuration done under

IMG --> PM & CS --> Maintenance Plans, Work Centers, Task Lists and PRTs -> Maintenance plans --> Set Maintenance Plan Categories

Created and assigned a distinct Number range to the same in SAN under:

IMG --> PM & CS --> Maintenance Plans, Work Centers, Task Lists and PRTs -> Maintenance plans --> Set Maintenance Plan Categories

c. Configuring a new value for Maint. Plan Sort Field (OPTIONAL)

Configured a Sort field IR0010 to denote Inspection Round based Plans for Plant 0010. This is Optional and has been done to keep the process distinct.

IMG --> PM & CS --> Maintenance Plans, Work Centers, Task Lists and PRTs -> Maintenance plans --> Define Sort Fields for Maintenance Plans

d. Settings for Costs at Operational Level

IMG --> PM & CS --> Maintenance & Service Processing -> Maintenance & Service Orders --> Functions & Settings for Order types -> Costs at Operation Level -> Define Cost Settings

Costs at Operation Level activated for Order type PM01, Plant 0010 only in SAN 100 (Sandbox) environment

e. Control parameters for Completion confirmation

IMG --> PM & CS --> Maintenance & Service Processing -> Maintenance & Service Orders --> Completion Confirmations -> Set screen templates for Completion Confirmation

Added Measurement/counter readings in Screen area 4 and Goods movements in Screen area 5. These functionalities will now be available under Time confirmation transaction

7. Process Steps

Step 1. Defining an Inspection Round

In SAP we create a General Task List for Route based work – Inspection Rounds for Multiple Equipments

Transaction code: IA05 (Create)/ IA06 (Change)/ IA07 (Display)

Follow screenshot below to check details of a defined Task List for regular Inspection workGroup 435, Group Counter 1

Task List Header Details – Filled as per any other Task List created as of now

Task List Operation Details – Similar as current Task Lists with an additional feature of assigning Different Equipments, Associated Functional Locations for Each Operation.

Measurement Points (say Pressure/Temperature sensing device) corresponding to Equipments at Operation level are assigned as PRTs

If the Task List is Strategy Based, Maintenance Packages (frequencies) are assigned to each operation

Save the Inspection Round – Task List

Step 2. Planning Inspection Round

Transaction codes: IP01 (Create Plan)/IP02 (Change)/IP03 (Display)/IP10 (Manual scheduling)/ IP30 (Auto scheduling through Deadline Monitoring)/IP15 (Change Maintenance Plans – List)/ IP16 (Change Maintenance Plans – List)

Maintenance Plan Category: IR

A Maintenance Plan is created and the Inspection Round (Task List) is assigned to the same.

In the Maintenance Plan Header, ideally assign the Functional Location of the Top Level Plant section under which the Routes are to be carried out. Each individual operation of Task List anyways carries specific Functional Location of the Equipments to be inspected.

Post creation of the Plan, it is scheduled, either manually (IP10) or in Background using Deadline Monitoring (IP30)

Execute Scheduling Overview Report (IP24 transaction) to get the scheduling overview and List of Order/Orders generated

Step 3. Executing Inspection Round

This step would comprise of- Further Planning the Maintenance Order with Spares, Services etc at Operation

level (if necessary)- Releasing Maintenance Order- Cost postings (Labour time confirmation, Goods issue), Measurement reading

entry (if relevant) against each Operation – linked to different Equipments or Common Equipments

As per configuration done, using the same Order Confirmation transaction IW41, users can post Time Confirmation, Goods Issue to Order, Measurement Point reading entry. against each operation rather than doing it through 3 different transactions

A critical advantage of using Operation Account Assignment instead of Header Account Assignment is:

Using Header Account assignment, you can assign multiple Functional Locations/Equipments using Objects Tab in Order <BUT> Costs can only be Planned, Posted and Reported at the Level of the Functional Location/Equipment under the Header Data using a single Maintenance Order

Using Operation Account Assignment, using a single maintenance order, you can Plan, Post actual costs, Report Costs (Planned/Actual) at individual OPERATION –> FLOC/EQUIPMENT level.

Order – Operation details

Select Individual Operation and Goto Internal tab to check individual Operation Account assignment and Operation level Costs. There will be an additional Tab Acct Assgt./Costs

You would also observe that Settlement rules are now set at individual operation level

i.e the Settlement rule icon will now appear at Operation level and not at Order header level as previously

There is a flexibility to set same settlement receiver for all Operation or set different settlement receiver for each operation.

As per current process also, for PM01 Orders, settlement objects –cost centres get automatically copied into the settlement rule section from Equipment assigned to Order header.

Same thing will happen even now, only difference being “As Equipments are assigned at Operation level” Cost centres of Equipments linked to each operation will get copied to settlement rules at individual operation level. If all Equipments belong to same cost centre, same cost centre would get assigned to individual Operation settlement rules. So there is no change in process as such, it’s just the Granularity level that has increased.

Notice in screenshot below. Settlement rules are at Order + Operation/Activity No level instead of Order Level (if Operation Account Assignment functionality is not used)

Time confirmation transaction – IW41 shown below

Note in Transaction screenshot below, that you can do Time confirmation entries, Goods Movement (Stock Goods Issue to Orders), Measurement documents entries in the single transaction by clicking on appropriate tabs. You can also cancel and go to next Operation to confirm by clicking on X + next

8. Reports

Some excellent standard reports are available which can provide you In depth details at Order + Operation Level.

Transaction: IW49N – Display Order and Operation details

Users can set their own Output Layout variant for the Report as per Output Column requirement

Transaction: IW40N – Display Operation Costs (with drilldown feature as per Cost value categories)