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R/3-System

Release Enterprise 4.7

Author:

Stefan Kroeger

September 2003

TPLM30

Case Study

Plant Maintenance

Instructor Guide

SAP AG TPLM30 Case Study

Contents:SAP Contact(s)................................................................................................................. 3Course Details .................................................................................................................. 3Duration............................................................................................................................ 3Course Materials and Other Materials ............................................................................... 3Country-Specific Units ...................................................................................................... 3Course Instructor Profile ................................................................................................... 3Level of Knowledge Required ........................................................................................... 3Training System................................................................................................................ 3Work in IMG (Customizing) ............................................................................................... 3User ID and Passwords for instructor ................................................................................ 3User ID and Passwords for course participants ................................................................. 3CATTs and Example ABAPs............................................................................................. 3Technical Hints ................................................................................................................. 31. General Introduction ..................................................................................................... 32. Background information on Sport Motorcycle AG .......................................................... 33. Description of Sport Motorcycle AG Group .................................................................... 34. Basic Data in the System .............................................................................................. 35. Requirements in the Subject Areas ............................................................................... 3


SAP Contact(s)WalldorfStefan KroegerRuediger KeilbachMichael Wieland

Course DetailsDuration5 days

Case Study – 4 days

Monday, 10.00 to 17.00

Tuesday - Thursday 9.00 to 17.00

Certification – 1 dayFriday – depending on local schedule

Course Materials and Other MaterialsManual for course particpants

Instructor guide

Instructor guides of standard courses PLM310, PLM315 and PLM316 can be used as a referencefor certain parts of the case study. They are available via SAPNet.

Country-Specific UnitsNone

Course Instructor ProfileExperienced instructor or consultant who is capable of teaching and demonstrating the complete scopeof SAP PM with its integration aspects.

Level of Knowledge RequiredInstructor must be familiar with the following courses in detail:

PLM300, PLM305, PLM310, PLM315, PLM316

or as an alternative the corresponding courses of R/3 Rel. 4.6C:

LO100, LO805, LO810, LO815, LO816 plus Delta course D47PM

Also, the instructor must have detailed knowledge of the processes in Materials Management as theintegration between Plant Maintenance and Materials Management is one of the major topics of thiscourse.Recommended courses for preparation:SCM500, SCM510, SCM525, SCM550


Training SystemClient

Only one client needed – all participants work in the same client

Data Required

Most data within Plant Maintenance will be created by participant during case study

Data within Materials Management required in Plant Maintenance (plants, storage locations,materials, BOMs etc.) will be created by participant during case study

Data within Financial Accounting and Controlling (Controlling area, cost center, company code etc.)will not be created by participant but rather used as offered by the IDES system. A hint is given forevery implementation step about which data to use.

Work in IMG (Customizing)Execute report ZSENQOFF using transaction SE38 so that participants can work in IMGsimultaneously.

User ID and Passwords for instructorInstructors should logon as user TPLM30 with password INIT. This user already exists in the mastersystem.

User ID and Passwords for course participantsCreate users TPLM30-00 to TPLM30-20 for the course participants using transaction ZUSR (fromtemplate user PM_TRAINING) with password INIT

CATTs and Example ABAPsNone

Technical HintsNone


Structure and Flow

The case study is structured into the following parts:

General introductionBackground information on Sport Motorcycle AGDescription of Sport Motorcycle AG GroupBasic data in the systemRequirements in the subject areas

Maintenance OrganizationManagement of Technical ObjectsMaintenance ProcessingPreventive MaintenanceControlling in Plant MaintenanceOptional (Reporting and analyses)

Note:

As participants work as project teams – and therefore at their own pace – there is no fixedschedule for the different steps within the case study.

However, all project teams must have finished their work until mid-day of day four so thatpresentations can take place in the afternoon of day four.


Day One

ApproximateTimesIncludingExercises

Contents: Units and Topics

30 min General Introduction

Background information concerning Sport Motorcycle Inc.

Start with implementation of requirements of Sport Motorcycle in the system

Days Two and Three



Implementation of requirements of Sport Motorcycle in the system - continued

Day Four



until mid-day Implementation of requirements of Sport Motorcycle in the system - continued

Presentations of project teams

Day Five



Certification


1. General Introduction

List of Topics in the Unit:Presentation of the particpants and the instructor

(Previous experience with SAP and PM, expectations of the course and so on)

Breaks

Advice on parking

Training documentation

Course objectives

Course ObjectivesThe course has two objectives:

1. Prepare junior consultant for his/her later work within a case study that allowshim/her to set up business processes in plant maintenance according to customerrequirements

2. Prepare junior consultant for certification

2. Background information on Sport Motorcycle AGIn this unit participants receive general information about their future customer andabout the customer’s motivation to implement SAP Plant Maintenance.

The objective here is to put participants into a realistic context which is typical fortheir future work as consultants.

3. Description of Sport Motorcycle AG GroupIn this unit participants receive detailed information about the company’s structure ingeneral and about the specific requirements of maintenance organization.

This is meant to be the starting point for participants from where to analyze thefundamental organizational requirements from a real life scenario and to “translate”them into SAP objects and settings.

4. Basic Data in the SystemIn this unit participants receive fundamental organizational data that have alreadybeen fixed and therefore do not have to be defined during the implementation ofSAP Plant Maintenance (these data are provided by the IDES system).

This simulates the situation in which project teams implementing SAP PlantMaintenance often find themselves in: the customer already has introduced financialaccounting, controlling and materials management and therefore has already made adecision about the major organizational units.

This is normally also true for the plants in manufacturing and materials management.


However, as the plants play an important role in maintenance organization as well, itis essential for PM consultants to be familiar with the handling of plants and storagelocations. Therefore they have not been predefined in this case study.

General

Controlling area 1000 EUROPE

Business area 1000 Mechanical engineering

Company code 1000 IDES AG

Purchasing organization: 1000 IDES Germany

Factory calendar 01 Germany

Plant MaintenanceCost center for technicalobjects 4110 Technical assets

Class for oil pumps ED113 (class type 002 – equipment class)

Serial number profiles PM1, PM2

Costing variant PM01

Costing sheet COPM

Materials Management

Material type HIBE (Operating Supplies)

Activate quantity and value updatefor material type Transaction OMS2

Activate valuation category C foreach plant Transaction OMWC


Valuation types for refurbishmentC1 - as newC2 - refurbishedC3 – defective


5. Requirements in the Subject AreasIn this unit participants will find the detailed requirements within the different areasand business processes:

- Maintenance Organization

- Management of Technical Objects

- Maintenance Processing

- Preventive Maintenance

- Controlling

- Reporting (optional)

Maintenance OrganizationIn this section it is essential to define the necessary plants with the required settingsand practice again the relationship between maintenance plant and planning plant.

As the definition of plants and storage locations has mainly to do with materialsmanagement, the required steps and settings are available to participants.

Also, it is essential that the required work centers are defined with the necessarysettings and are assigned to the right plant.

Objects to be Created – Organization

Plant I Hamburg-Lockstedt HL##

Plant II Hamburg-Wilhelmsburg HW##

Maintenance planner P##

Materials warehouse at plant I ML##

Mechanical workshop ME##

Electronics workshop EL##


Objects to be Created – Technical Objects / Materials

Functional Location structure ?

Equipments ?

Coolant lubricant pump material KP##

Batches (valuation types) of coolantpump KP## for split valuation C1, C2 and C3

Spare parts DI-##, FL-##, AN-##

BOMs ?

Customizing Steps Required for Materials Management

Define storage locationEnterprise Structure > Definition >Materials Management > MaintainStorage Location

Define quantity and value update

Logistics – General > MaterialMaster > Basic Settings > MaterialTypes > Define Attributes ofMaterial Types

Define account determination

Materials Management >Valuation and AccountAssignment > AccountDetermination > AccountDetermination Without Wizard >Group Together Valuation Areas(entry without valuation groupingcode)

Maintain plant parameters forinventory management

Material Management > InventoryManagement and PhysicalInventory > Plant Parameters

The following list contains the sequence of steps for creating a new plant and anew storage location as areference for the instructor.

As the creation of plants and storage locations is not part of the PM courses theinstructor can give hints to participants. However, this should not bedemonstrated from the start. Participants should rather work on thisrequirement first.


1. Define plants HL## and HW##Enterprise Structure > Definition > Logistics – General > Define, copy, delete, checkplant

2. Maintain planning plantEnterprise Structure > Definition > Plant Maintenance > Maintain maintenanceplanning plant

3. Define storage location in plant HL##Enterprise Structure > Definition > Materials Management > Maintain StorageLocation

4. Assign plant to company codeEnterprise Structure > Assignment > Logistics – General > Assign plant to companycode

5. Assign purchasing organization to plantEnterprise Structure > Assignment > Materials Management > Assign purchasingorganization to company code

6. Assign standard purchasing organization to plantEnterprise Structure > Assignment > Materials Management > Assign standardpurchasing organization to plant

7. Assign maintenance planning plant to maintenance plantEnterprise Structure > Assignment > Plant Maintenance > Assign maintenanceplanning plant to maintenance plant

8. Define quantity and value update (for material type HIBE in valuationareas (=plants in this case) HL## and HW##)

Logistics – General > Material Master > Basic Settings > Material Types > DefineAttributes of Material Types

9. Define account determination > enter valuation grouping code 0001 forvaluation areas HL## and HW##

Materials Management > Valuation and Account Assignment > AccountDetermination > Account Determination Without Wizard > Group TogetherValuation Areas

10. Maintain plant parameters for inventory management (use plant 1000as a reference)

Material Management > Inventory Management and Physical Inventory > PlantParameters

11. Activate split valuation > split valuation by status (C) for both plantsMaterials Management > Valuation and Account Assignment > Split Valuation >Activate Split Valuation

12. Define plant parameters for MRP > copy parameters of plant 1000Materials Management > Consumption-Based Planning > Plant Parameters > CarryOut Overall Maintenance of Plant Parameters

Maintenance Organization - Technical Objects / Materials

Participants have to develop an appropriate structure consisting of functionallocations, equipments and BOMs to meet the requirements of Sport Motorcycle AG.

The structures created by participants are to be discussed during the presentations on


day four. There is no model solution provided in the system.

Material KP## (Coolant pump)

Make sure the material is prepared for refurbishment already during the creation ofthe material master. Enter valuation category C (status) into tab strip Accounting 1.

After saving the material master valuation types C1, C2 and C3 can be created byadding material KP## again with tab strip Accounting 1 selected. Make sure youbring up Organizational levels to be able to make an entry in the field valuation type

Availability check for coolant pump (KP00):

Make sure you enter a value for the availability check in the material master(MRP3): either daily requirements (01) or individual requirements (02).

Goods receipt of coolant pump KP00:In transaction MIGO, Goods receipt - Others can be used together with movementtype 501. Make sure you enter valuation type C1 on tab strip Material after you havespecified plant HL## and storage location ML##.

Hints for equipments created automatically during goods receipt:- make sure to enter correct maintenance plant in equiment master

- if serial number profile PM2 is used in material KP00, equipment category Z ispredefined

- equipment category Z uses a user status profile where status PLA and status TSTdo not allow installation of equipment into a functional location

>>change user status to PRD before trying to install equipment

Maintenance ProcessingIn this section maintenance processing has to be set up according to the requirementsof Sport Motorcycle. That means that notification processing as well as orderprocessing has to be defined.

The maintenance processing part consists of the following parts:

- create new notification type ##

- assign necessary paramters to new notification type ##

- create new order type IH##

- assign necessary paramters to new order type IH##

- make existing order type (PM04 - refurbishment) available in the new planningplant

- complete parameters for order type PM04 in the new planning plant

If questions arise in this part, the instructor guide of standard course PLM315 can beused as a reference.

In more detail, the following data have to be created by participants:


Objects to be Created – Maintenance Processing

Notification type ##

Code group for internal damage S##

Code group for internal cause codes U##

Code group for internal object parts O##

Code group for internal activities(actions) T##

Internal catalog profile BS##

Order type IH##

Specific Customizing Steps - Maintenance Processing

Define condition-valuation(refurbishment)

Production > Shop Floor Control >Integration > Define Valuation ofGoods ReceivedEntry in the new maintenanceplanning plant with the samevaluation variant as that for plant1000, 007)

Documentation on goods movementsfor the order

Plant Maintenance and CustomerService > Maintenance and ServiceProcessing > Maintenance andService Orders > Functions andSettings for Order Types > GoodsMovement for Order > DefineDocumentation for GoodsMovement for the Order(Entries are similar to those fororder type PM04 in plant 1000)


Maintenance Processing - Refurbishment

Hints for refürbishment:

- change master batch in serial number to C3 before executing transaction IE4N(dismantling of equipment / moving to stock)

- assign oder type PM04 to planning plant HL##

- complete settings for order type PM04 and plant HL##: scheduling, costingparameters, completion confirmation

Preventive Maintenance

In this section preventive maintenance has to be implemented according to therequirements of Sport Motorcycle.

The central issue here is to properly schedule different maintenance plans.

In more detail, the following objects have to be created and the followingcustomizing steps have to be performed:

Objects to be created - Preventive Maintenance

General task list ?

Change number for task list ?

Time-based maintenance plan ?

Performance-based maintenance plan ?

Specific Customizing Steps - - Preventive MaintenanceCheck / modify existing maintenanceplan categories ?

Define sort field ?

Define Default Order Types forMaintenance Items IH##


Controlling in Maintenance

In this section the settings for costing and settlement of an order have to be madeaccording to the requirements of Sport Motorcycle.

This has to be done both for the new order type IH## as well as for order type PM04(refurbishment).

Objects / Customizing steps - ControllingAssignment cost elements - valuecategory check / modify existing assignment

Costing variant order types IH##,PM04

check / modify existing variant orcreate new one

Costing sheet order types IH##,PM04

check / modify existing costingsheet or create new one

Default settlement rule order typesIH##, PM04 ?

Settlemente profile order types IH##,PM04

check / modify existing profile orcreate new one


Optional (Reporting and Analyses)

In this section an exception in the Early Warning System (EWS) has to be createdbased on the planned costs in the new planning plant.

Following you find an example :Create an exceptionFor example, total planned costs in maintenance plant HL## exceed 1,000,000Euros> Logistics-PIant maintenance-Information systemEarly warning system-Exception-Create> Enter number and description> Info structure, for example S061 or S115> Select characteristics, for example, Maintenance plant> Characteristic values > for example, HL##> Requirements button > Select indicator, for example, Total planned costs> Define Requirement button > Threshold value analysis> Enter requirement; then set currency (Euro)> Follow-up processing button > Area – Standard analysis > Color in list >Set to 3 (red); Area – Periodic analyses > Activate for periodic analyses;Send mail > Enter R/3 user > Save exceptionCreate a periodic analysisEarly warning system-Periodic analysis-Analysis area-Create> Determined by the system> Create variant (with maintenance plant HL##)Schedule an exception in periodic analysisEarly warning system-Periodic analysis-ScheduleSet date/time and periodic values (for example, execution hourly)Create an order and enter a completion confirmation, which fulfils theexception criterion (planned costs > 1,000,000)

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