Pm End User Manual

End User Manual Title: SAP PM Module: Release: Created by: Created on:

PLANT MAINTENANCE ECC 6.0 RAVINDER KUMAR 23 Nov‟10

Project Sarthak

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S.No.

Page No.

1.

Introduction Introduction ............................................ .................................................................. ............................................ .......................................... .................... 4

2.

Getting Started ........................................... ................................................................. ............................................ ...................................... ................ 6

3.

Master Data ............................................ .................................................................. ............................................ ........................................ .................. 18 3.1

Functional Location ..................................................................... .............................................. 18

3.2

Equipment ............................................................... ................................................................. .. 29

3.3

Equipment Bill of Material ................................................ ........................................................ 43

3.4

General maintenance Task T ask lists .................................................................................................. 50

3.5

Work Permit P ermit ............................................................ ................................................................. .. 59

3.6

Characteristic .......................................................................................... ................................... 67

3.7

Measuring Points ....................................................................................................................... 71

3.8

Work Center ............................................................ ................................................................. .. 80

3.9

Maintenance Planning ........................................................ ........................................................ 85

3.10

Maintenance Plan Scheduling ....................................................................................... ............. 92

4.

Maintenance Maintenance Processing Processing ........................................... ................................................................. ......................................... ................... 102 4.1

Measuring documents ............................................................................. ................................. 102

4.2

Breakdown Maintenance Process: .................................... ....................................................... 123

4.3

Preventive Maintenance ................................................................................................ ........... 160

4.4

Regular Maintenance : ................................................................. ............................................ 203

4.5

Calibration Process: ................................................................................ ................................. 209

5.

Plant Maintenance Maintenance Information System .......................................... .......................................................... ................ 217 5.1

Standard Reports ................................................................................................ ...................... 217

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1. Introduction SAP R/3 is an “integrated and industryindustry-independent standard software” software” which covers integrates and connects all functional areas in a business. SAP AG defines integration as "defined communication". Although R/3 is designed for complete integration, it can also be used for a couple of business areas.

SAP is the abbreviation for “Systems Applications Applications and Products in Data Processing”.

The purpose of this document is to provide an overview of SAP PM Functionality and the details of how the transactions are carried out in SAP R/3.

The document has been organized as follows;



Master data maintenance required for PM module is covered covered first. Master data maintenance is the most important aspect as these t hese data affects all the transaction where that Master data is used. It is very much controlled by authorizations as per the policy of the company.



As a PM user, you you will be using various transactions to replicate day-to-day work work in SAP R/3. So all the transactions, which are relevant to you for carrying out Plant Maintenance activities, are covered in this.

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Master data maintenance and transaction processes are explained with the help of SAP screen Shots. This will help you in executing the same perfectly.

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2. Getting Started LOG ON:

Select SAP Log in Icon

On PC Desktop & press enter key or double click,

Or follow the menu path as shown in following screen:

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The following screen will appear.

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Select Server and click on Log on icon

Logging onto the SAP R/3 system



Sap R/3 systems are client systems. The client enables you to run several business operations at the same time in one SAP R/3 system.



Client is, in organizational terms, an independent unit in the system. Clients have their own data environment and therefore their own user master and transaction data, assigned user master records and chart off accounts and specific customizing parameters.



So that you log on to SAP R/3 system, you must have a master record created for you for corresponding client. For reasons of access

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protection, you must enter a password when you log onto the sap system. The system does not display the password you enter. 

SAP R/3 system is available in several languages. Use the language input field to select the logon language for each session.

Elements of the screen layout



Command Field: Use command field (hidden as default) to go to applications directly by entering the transaction code.



Standard Tool Bar: the push buttons in the standard tool bar are found on every screen in an SAP R/3 system. Any push buttons that cannot be used in a particular application are grayed out. If you place your

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cursor on a push button for a while the system displays a quick info text that explains the push button function. 

The Application Tool bar : shows which functions are available in the current application.



A Tab page: provides a clearer overview of several information screens



Status bar: the status bar displays information on the current system status, for example. Warning or error messages



Menu bar: the menus shown here depend on which application you are working in.



Title bar : the title bar displays the functions that are available for the user.



Checkboxes: checkboxes enable you to select several options simultaneously within a group.



Radio Buttons: allow you to choose exactly one item form a selection.

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The below shown screen gives you a detail explanation. Menu Standard Title bar

Command

Application toolbar Tab Page

Input Fields Check boxes,

Status

SAP Easy Access



Sap easy access is the standard entry screen displayed after the logon. You navigate through the system using the tree structure.

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You are greeted by your logo in the right-hand part of the window

Selecting Functions 

You can call functions in the system as follows o

Menu Option

Favourites

o

o

Entry in the SAP easy Access menu



“/n” ends the current session



“/i” delets the current session



“/oCV01N” opens a new session and branches out to the transaction specified (CV01N)

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


By entering “ search_sap_menu” in the command field, you can display menu paths for the desired SAP transaction.

Command Field

Menu SAP easy Access and Favorite List

Field help : F1 and F4



Use F1 to display an explanation of fields, menus, functions and messages.



F1 Help also provides technical information on the relevant field.

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F1 Help



Use F4 to display possible inputs . you can also access F4 help for a selected field using the button immediately to the right of that field.

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F4 help

User – Specific Personalization



The end user has many possibilities for personalizing the system. For example as shown in the screen below.

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SAP – Symbols or icons

Button

Keyboard

Description

Shortcut Enter Key

Ctrl + S

Button

Enter/Continue Save database

to

Keyboard

Description

Shortcut Ctrl

+

Page First page

Up Page Up

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F3


Back

Shift + F3

Exit

Page Down System

Task

Ctrl

+

Page

Down

Next page

Last page Create

F12

Cancel

None

Ctrl + P

Print

None

Ctrl + F

Find

F1

Ctrl + G

Find next

Alt + F12

New

session

Create

shortcut

on Desktop F1 Help

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Customize Local Layout

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3. Master Data 3.1 Functional Location Functional locations are elements of a technical structure (for example, functional units within a system). Functional locations can be created according to the hierarchy, and can be structured based on the f ollowing criteria: 

Functional



Process-related



Spatial

Each functional location is managed independently in the system, to : 

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

Trigger: Functional locations need to be structured according to functional, process-related or spatial criteria. Whenever any new location identified we need to create Functional location.

BUSINESS PROCESS PROCEDURE OVERVIEW A functional location is an organizational unit to structure the maintenance objects of a company according to functional, process-related or spatial criteria. Last changed on:

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BUSINESS PROCESS PROCEDURE OVERVIEW A functional location represents the place at which equipment(s) can be installed and a maintenance task is to be performed.

Output – Results

Comments

Functional location created

Procedural Steps

Title: Maintaining of Master data – functional

ID: PM

location Business process: Transaction IL01, IL02

Functional Location

code: Menu

path:

Logistics

Plant

Management of Technical Objects location

maintenance functional

Create (IL01)

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Description: Use this transaction for creating structured location Double CLICK on selected line or press Enter to get following screen

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Instructions In the initial screen, enter the values in the following fields:

Required

Field name

User action and allowed values

/ Optional Functional location

R

Functional location code is to be entered as per the structure

Structure indicator

R

Structure of func. With hierarchy level

Fuct. loc. cat.

R

Type of fictional loc.

“Press enter key“ or click on icon

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Field name


Required


Optional Description

Functional Location. Name is to be entered

R

(40characters). If the name exceeds, use long text.

Ensure General data screen is open or click on GENERAL TAB

Field name

Required


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Optional

Weight

O

Weight of the Functional Location

Size

O

Size of the Functional Location

Start up date

O

Actual start date of usage

Acquisition value

O

Value of the Functional Location at the time of acquiring

Acquisition date

O

Date on which the Functional Location was acquired

Manufacturer

O

Manufacturer of the Functional Location

Manufacturing

O

Country, where the Functional Location was

country

manufactured

Model number

O

Model number of the Functional Location supplied by the manufacturer

Constr. Yr/mth

O

Year

and

month

of

Functional

Location

constructed Manuf Part No.

O

Part number of the Functional Location as supplied by the manufacturer

Manuf Serial No.

O

Serial number of the Functional Location as supplied by the manufacturer

After entering required data click on LOCATION TAB

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Required

Field name


Optional Maintenance plant

O

Maintenance

plant,

where

the

Functional

Location is located Location

O

Location of the Functional Location, for ex: Building where it is installed.

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Field name


Required


Optional Plant section

O

Further low level identification of location.

Work center

O

Production work center, for blocking from production during maintenance work.

ABC Indic

O

As detailed below :

After entering required data click on ORGANISATION TAB

TO GET FOLLOWING SCREEN :

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Field name


Required


Optional Company code

R

R/3 will copy the respective company of the maintenance plant.

Business area

O

For viewing profit and loss statement/area wise costing.

Asset

O

Appropriate asset number should be assigned to the Functional Location.

Cost center

O

All the costs incurred at the Functional Location level are collected at these cost centers level.

Planning Plant

O

Maintenance planning plant, defaulted as that of maintenance plant.

Planner group

O

Planner

groups

as

per

the

maintenance

planning activities. Maintenance

work O

center Catalog profile

Maintenance work center, currently represents the departments like ME, EE, IE, CE & SE

O

For Functional Location history generation all the codes are maintained in a catalog profile.

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After entering required data click on STRUCTURE TAB You will reach the following screen

Required

Field name


/ Optional Functional Location

O

Functional location under which the Functional Location is functioning.

Superior Functional O

Superior Functional Location under which the

Location

Functional Location is functioning.

Tech Ident. no

O

Technical

identification

number

of

the

Functional Location. Const Type

O

Material of construction.

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Click on


to

Save and following message will be given by

the system

The Functional Location is saved.

Through transaction code IL02, required functional location can be opened for editing If Functional location installation is to be changed, click on icon on structure tab, to get the following screen

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First dismantle the already existing installation and then input / select new installation location and click on

Click on

Enter / Continue icon

to

Save the changes made and following

message will be given by the system.

3.2 Equipment A piece of equipment is an individual object that is to be maintained independently. Each piece of equipment 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 Pieces of equipment can be installed and dismantled at functional locations. The usage times for a piece of equipment at a functional location are documented over the course of time.

Trigger: Maintenance history needs to be captured for a physical technical object.Whenever any new Machine/Computer etc. Purchased we need to create Equipment Master. Correct Equipment Type has to be choosen always for proper functioning.

BUSINESS PROCESS PROCEDURE OVERVIEW Last changed on:

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BUSINESS PROCESS PROCEDURE OVERVIEW This document describes how to create Equipment for use in PM functions. Equipment are master data to manage physical objects in PM and Customer Service. An Equipment master data object must be created here before it may be associated with a Functional Location object.

Output - Results

Comments

Equipment Master created

ID: PM Transaction

Title: Maintaining of Master data - Equipment code: Menu

IE01, IE02, IE03,

path:

Logistics

Plant

Management of Technical Objects

maintenance Equipment

Create (IE01)

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Description: Use this transaction for creating & maintaining Equipment Double click or press Enter Key to reach the following screen

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Instructions In the initial screen, enter the values in the following fields:

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Required

Field name


/ Optional No in put is required as system creates an

Equipment

internal no, Valid on

R

By default system proposes current date, one can change to the appropriate valid from date.

Equipment category R

Appropriate equipment category to be selected from the list

REFERENCE Equipment

O

Already existing equipment can be used to copy the data Not

Material

applicable

this

is

required

when

a

material/equipment link is required

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Press Enter key or click on

Enter / Continue icon to reach the following

screen

Enter the parameters as detailed below: in „General‟ screen Screen fields data entry instruction: Field name

Required


/ Optional Description

R

Equipment

Name

is

to

be

entered

(40characters). If the name exceeds, use long text. Object type

O

Type of machine ex: “select from list”

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Required

Field name


/ Optional

Weight

O

Weight of the equipment

Size

O

Size of the equipment

Start up date

O

Actual start date of usage

Acquisition value

O

Value of the equipment at the time of acquiring acquiring

Acquisition date

O

Date on which the equipment was was acquired

Manufacturer

O

Manufacturer of the equipment

Manufacturing

O

Country,

country

where

the

equipment

was

manufactured

Model number

O

Model number of the equipment supplied by the

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Required

Field name


/ Optional manufacturer Constr. Yr/mth

O

Year and month of equipment constructed

Manuf Part No.

O

Part number of the equipment as supplied by the manufacturer

Manuf Serial No.

O

Serial number of the equipment as supplied by the manufacturer

Click on

Location Tab to get the following

screen

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Required

Field name


/ Optional Maintenance plant

R

Maintenance plant, where the equipment is located

Location

O

Location of the equipment, for ex: Building where it is installed.

Plant section

R

Further low level identification of location.

Work center

O

Production work center, for blocking from production during maintenance work.

ABCD

Indicator

O

As detailed below:

Strategy

A

Critical

B

Important

C

Non-critical

Now Click on

Organization tab tab to get the following

screen

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Required

Field name


/ Optional Company code

R

R/3 will copy the respective company of the maintenance plant.

Business area

O

For viewing profit and loss statement/area wise costing.

Asset

O

Appropriate asset number should be assigned to the equipment.

Cost center

R

All the costs incurred at the equipment level are collected at these cost centers level.

Planning Plant

O

Maintenance planning plant, defaulted as that of maintenance plant.

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Required

Field name


/ Optional Planner group

O

Planner

groups

as

per

the

maintenance


work O

center

Maintenance work center, currently represents the departments like ME, EE, IE, CE & SE

Catalog profile

O

For equipment history generation all the codes are maintained in a catalog profile.

Now Click on

Structure tab to get the following screen

Click here for Installation at functional location

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Required

Field name


/ Optional Functional Location

O

Functional location under which the equipment is functioning.

Superior Equipment

O

Superior equipment under which the equipment is functioning.

Tech Ident. no

O

Technical

identification

number

of

the

equipment. Const Type

O

Material of construction.

The field in the Function location blank, so it is to be selected for the Hierarchy Icon.

Click on icon

on structure tab, to get the following

screen

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First dismantle the already existing installation and then input / select new installation location and click on


If you select the Superior Equipment Instead of Functional Location then that Equipment will be called SubEquipment.

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WARRANTY END DATE

WARRANTY START DATE

Click on

to

Save the Equipment and following message

will be given by the system

Warranty is the commitment of the manufacturer, vendor, or retailer to guarantee services to a customer either free-of-charge or only charged in part, over a certain period of time.

Warranty details of equipment can be incorporated during equipment creation or can be done in equipment data change transaction and can be viewed through display mode

Whenever we try to create a notification or order, SAP system will alert with a warning message with warranty details if the equipment is still under warranty [period Last changed on:

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To accommodate different warranty conditions against different warranty services, a separate master warranty is to be created and the same is to be assigned to the equipment master data

Required

Field name


/ Optional Master Warranty

O

N.A

Begin guarantee

O

Start date of warranty

Warranty end

O

End date of warranty

3.3 Equipment Bill of Material A “Bill Of Material” (BOM) is a complete, formally structured list of the components making up a technical object or an assembly. The list contains the object numbers of the individual components together with their quantity and unit of measure. The components can be stock or non-stock spares or assemblies, which in turn can be described using maintenance BOMs. BOMs are primarily used for the following purposes: 

Structure description BOM describes the structure of a technical object or material. Using maintenance BOMs maintenance tasks can be planned



Assignment of spare parts BOM is used in plant maintenance to assign spares for a technical object or material. This is shown in the figure below: Last changed on:

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Trigger: A piece of maintenance equipment requires a bill of material for maintenance purposes.Whenever any Equipment created we can create its BOM for Structuring. But Before creating Equipment BOM we need to create Material Master.

BUSINESS PROCESS PROCEDURE OVERVIEW Create a bill of material for a piece of maintenance equipment to describe the equipment components, maintenance requirements or the assignment of spare parts.

Output - Results

Comments

Equipment BOM created

ID: PM

Title: Maintaining of Master data – Equipment

Business process:

Bill of Material

Transaction

Menu

code:IB01, IB02

Management material

path:

Logistics of

Plant

Technical

Equipment BOM

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maintenance

Objects

Bill

of

IB01 create

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Description: Use this transaction for creating & maintaining Equipment bill of material

Press Enter key or use mouse double click to get following screen

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Equipment no

Plant BOM USAGE

Press enter key In the initial screen, enter the values in the following fields: Field name

Required User action and allowed values / Optional

Equipment

R

Select Equipment for which BoM

is being

created Plant

R

Enter plant

BOM usage

R

Select – 4 for Plant Maintenance

Press Enter Key or Click on


To get the following screen

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Enter the parameters as detailed below : in „Material‟ screen Screen fields data entry instruction: Required

Field name


/ Optional Item category

R

Select Item Category

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Field name


Required


/ Optional

Component

R

Select item code

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Field name


Required


/ Optional

Component

R

description

System

defaults

description

of

selected

component

Quantity

R

Enter installed quantity

Units

R

System defaults UOM of selected component

Click on

to save the entered data

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3.4 General maintenance Task lists Task Lists. Task list is defined as the set of work instructions that will help a maintenance planner schedule his day-to-day job in a predefined manner Maintenance task lists describe a sequence of individual maintenance activities, which must be performed repeatedly within a company. Task l ists are used to standardize these recurring work sequences and to plan them more effectively. Task lists can be grouped, for example in to two groups -

"Inspection" and

"Mechanical Repairs". The individual maintenance task lists within the group "Mechanical Repairs" and are identified by the task list counter numbers 01 and 02 as shown in following fig.

General Maintenance Task List This type of task list is generic in nature i.e. the same general task list can be used both for

equipment and functional location and also for more than one

equipment or functional location of the same type or different types. Similar general task lists can be grouped and several individual general maintenance task lists can be created. General task lists can be used to reduce the time spent creating individual functional location/equipment task lists.

Trigger: Need to prepare a sequence of activities that must be repeatedly performed within a company.

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BUSINESS PROCESS PROCEDURE OVERVIEW Maintenance task lists describe a sequence of individual maintenance activities which must be repeatedly performed within a company. They are used to standardize repetitive work processes, to plan them more effectively, and to save time when creating maintenance orders and maintenance plans.

Output – Results

Comments

General Task List created

For General Task Lists Title: Maintaining of Master data - Functional

ID: PM

location Business process: Transaction IA05

General Task List

code: Menu

path:

Logistics

maintenance preventive scheduling lists

task list

maintenance

Plant Work

General maintenance Task

Create (IA05)

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Description: Use this transaction for creating & maintaining General task list Press Enter Key to get the following screen

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Field name


Required


/ Optional Group

R

Enter a group name (8 characters only)

Profile

R

PDIL

Key date

R

Date from which the task list is to be used

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Enter the field value according to the following table Required

Field name


/ Optional Group CNTR

R

System defaults grp cntr is to be entered

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Work Center

O

Select responsible work center from the list

Usage

O

Select 4 for plant maintenance

R

Select 4 for plant maintenance

Status

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Click on operation tab

Following screen can be viewed

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In the initial screen, enter the values in the following fields:

Field name

Required


/ Optional Work center

R

Select work center

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Plant code


R

Define plant code like for Noida Engineering= 1100

Ctrl key

R

Pm 01 for internal operations & PM 03 for external operations

Operation

O

Describe the operation to be carried out

O

System

description Work

will

automatically

calculate

by

calculation key UN

O

Unit of measurement for mh

NO

O

No of persons required to perform the activity

Duration

O

Duration of Operation

Unit

O

Unit of measurement for duration

C

O

Calculation key –2

( for calculating duration )

Repeat the same above operation for required no of activities

Select components tab for allotting spares required for that acti vity.

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Material

O

Select required item code

Qty

O

Enter the required qty

Click on

to save the task list.

3.5 Work Permit Permits are to ensure that special approval must be obtained before maintenance orders are executed.

Permits can be assigned to the following objects: 

Technical objects (functional locations and equipments)



Maintenance orders

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Permits can be grouped into permit categories, like 

Work permit – General jobs



Hot work permit - Hot job



Confined space work permit - permit to work at confined areas



High reach work permit-Permit to work at elevated places

Trigger: A regulation or condition needing to be observed when maintenance work is being performed.

BUSINESS PROCESS PROCEDURE OVERVIEW A permit is a regulation or condition that must be observed when maintenance work is to be performed on a technical object. The creation of the permit master record is covered in this procedure. The permit can be attached to a Functional Location, Equipment master, or directly t o a work order. The requirement can be observed at the release or the completion of a work order. The permit can only be for reference, provide a warning, or cause an error message unless issued.

Output – Results

Comments

Permit master created

Master record can be viewed again by selecting row and choosing details.

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ID: PM

Title: Maintaining of Master data – Work Permits

Business process:

Work permits

Transaction

code: Menu path: Logistics

IPMD

objects

Environment

Management of tech. IPMD permits

Select the transaction as shown in the following screen

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To view the next screen press Enter key or click on icon

AND THEN ON

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Enter the filed values as explained in following table :

Field name

Required


/ Optional Permit

R

Enter permit name

Text

R

Enter description of the permit

Category

R

Select category of permit from the list

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Required

Field name


/ Optional

Order release

O

Select required control on order releasing from the drop down list

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Required

Field name


/ Optional about the issue of assigned permit to the order

2 – Order release is possible after issuing the permit only

(Blank) – No need for issue of Permit

Order Completn

O

Select required control on order releasing from the drop down list

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Required

Field name


/ Optional warn about the issue of assigned permit to the order

2 – Order completion is possible after issuing the permit only

(Blank) – No need for issue of Permit Permit class

R

System defaults Permit class

Print

O

Select the Print

Not modifiable

O

N.A

Click on

If you want to write some more thing about the permit. You can use the Long Text.

Maintain required permit instructions and click on ICON

Click on save button

to save the Permit.

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3.6 Characteristic The pre-requisite for creating a Measuring Point is characteristic.

Creation of a Characteristic: The Pre-requisite for creating a characteristic is “Unit of Measurement”, and almost all standard “units of measurement” are available in the system. If a standard Unit of Measurement is not available, contact administrator for creation of the same.

Trigger: Format need for characteristic values and the need to display characteristics when classifying master data

Output – Results

Comments

List of characteristics

Used to classify and identify objects

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Double click or press Enter Key to reach the following screen


Required

Field name


/ Optional Characteristics

R

Select characteristics & characteristic screen appear & (If you want to change a Existing Charecteristic) Select find by group & click. The next screen appears & select plant maint. From drop down list. If you want to create a new characteristic

please

enter

the

new

characteristic name and then go to the menu bar “Charecteristic” and click on “new”

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Field name


Required


/ Optional

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Field name


Required


/ Optional

After selecting the above screen double click you get the following screen. Then select the required characteristic & double click

Change no

O

If require fill

Validity

O

Select the date of validity from the calendar

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Field name


Required


/ Optional

If the values are of standard type , values can be entered e.g., Speed of pumps  1500

RPM, 3000 RPM, 1000 RPM, 750 RPM etc.,

OR

If Make is a characteristic, the values could be  Akay, KSB. Maag etc.,

Click on

The Characteristic is saved.

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Measuring Points:

Measuring points in MY SAP ERP System describe the physical and/or logical locations at which a condition is described (for example, the feed water temperature of a boiler, or the number of run hours of a machine) In Plant Maintenance, measuring points are located on technical objects, in other words, on pieces of equipment or functional locations. Measuring points are classified into: Measuring points Normal inspection points like temperature, pressure readings Counters Counter is a provision in my SAP ERP to represent the wear and tear of an object, consumption, or the reduction of an object‟s useful life Counters can be used to accumulate the readings like equipment run hours, Energy Consumption readings, etc.

Trigger: A measurement or counter reading for any Equipment/ Functional location to capture its current condition.

Business Process Procedure Overview Measurement will be at a measuring point or a counter.

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Output – Results

Comments

Measurement Point created

Creation of Measuring Point : Measuring Points can be created for Functional location and Equipment.

ID: PM

Title: Maintaining of Master data - Equipment

Business process:

6.4.1.7 – Measuring Points

Transaction

Menu

code:IK01

Management

path:

Logistics of

Plant

Technical

Environment Measuring point

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maintenance Objects

Create (IK01)

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Case 1 : Normal Measuring Point

As shown in the following screen, Select the transaction


Meas. Point cate or

Screen fields data entry instruction: Required

Field name


/ Optional Measurement

R

Object

Select IEQ for equipment /IFL for Functional Location. Now press enter key if corresponding field is not displayed as per IEQ or IFL

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Required

Field name


/ Optional Equipment / fuct.loc

R

Equip/Flo code is to be selected

Meas Pnt Cat

R

Select required cato. Or use gen cato.

Measuring

point O

counter check box

Select if measuring point is counter or leave blank

Press Enter Key or click on

Details icon to reach the following

screen

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Required

Field name



O

Position

Position

of

the

measuring

point

on

the

equipment or functional location.

Characteristic

R

Characteristic for Unit of Measurement

Name Description of the R

Detailed description of the measuring point

measuring point Target Value

O

Normal operating value should be entered: Example: 10.0kg/cm2

Text

O

Text can be entered: Example: Pressure under ambient condition.

If measuring point is normal measuring point and if data like max. and min. range is to be given then click on Additional data tab. This data will determine for automatic generation of notification whenever entered reading is beyond extreme limits.

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Additional data TAB

Go to : Additional data for entering Maximum and Minimum Values :


Field name


/ Optional Upper Range Limit

O

The Maximum pressure condition

Lower Range Limit

O

The Minimum pressure condition

Click on

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C a s e 2 : M ea s u r i n g P o i n t a s Co u n t e r

Check this box measuring point counter

if the is a


Field name



R

Object

Select IEQ for equipment /IFL for Functional Location. Now press enter key if corresponding field is not displayed as per IEQ or IFL

Equipment / fuct.loc

R

Equip/Flo code is to be selected

Meas Pnt Cat

R

Select required cato. Or use gen cato.

Measuring

point R

Select Check box

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Required

Field name


/ Optional counter check box

Press Enter Key to view the following screen

Counter over reading / Reset value Annual Estimate Note : This is required for Counter based planning

Screen fields data entry instruction:

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Required

Field name



O

Position

Position

of

the

measuring

point

on

the

equipment or functional location.

Characteristic

R

Characteristic for Unit of Measurement

Name Description of the O

Detailed description of the measuring point

measuring point Counter Reading

O

Max displayable reading of the counter

Annual Estimate

O

Annual Estimate of readings

Click on The Measuring Point (Counter) is saved.

3.8 Work Center Trigger: Need identified for a new Work Center within a plant.

Business Process Description Overview A work center is an organizational unit that defines where and when an operation should be carried out within a plant. A work center is unique within a plant. Work centers can be machines, people or production lines. Operations that need to be executed are defined on a task list and executed at the corresponding user assigned work center. This transaction enables the user to create basic data, set defaults, assignments, and define capacities and scheduling data pertinent to a work center. Last changed on:

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Work centers contain default values that are copied or referenced in operations at the time of task list creation. They also contain costing, scheduling and capacity data required for leadtime scheduling and capacity planning.

Output – Results

Comments

New work center within a plant

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3.9 Maintenance Planning

Mainten ance Plan (Single Cyc le):

Single cycle plan allows only one cycle frequency, whereas strategy plan allows multiple frequencies. Single cycle maintenance plan adopts exactly one time-based or performance based maintenance cycle, with interval at which the maintenance plan should be executed.

Trigger: To plan maintenance events to occur in a regular, periodic manner, based on one cycle parameter.

Business Process Procedure Overview Maintenance plans merge the records of specific strategies, task li sts, items and measuring points (when necessary) to generate a recurring maintenance schedule for the resultant orders which are copied from the task lists. In addition, they can be used for condition-based maintenance which can generate notifications or orders based on pre-established performance parameters. There can be multiple maintenance items in a maintenance plan. A separate order will generated from the plan for each item.

Output – Results

Comments

Maintenance plan is created.

The outputs of all three types of maintenance plans

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are work orders (and notifications) automatically created based on pre-established work requirements and planning parameters. In addition, the upcoming maintenance can be budgeted. You will be able to look at what orders are coming due in up to the next several days, months or years (scheduled calls). In addition, you can use date monitoring to create the orders as far in advance as necessary. In this case, all the maintenance events produced from this type of plan will be due with at the same time and in the same frequency. Refer to business process procedure „Display Maintenance Plan‟ to verify results.

Title: PREVENTIVE MAINTENANCE –SINGLE CYCLE

ID: PM

PLAN Business process: Transaction IP41

6.4.2.2 – Single cycle Maintenance Plan

code: Menu

path:

Logistics

Preventive maintenance Maintenance Plans

Plant

maintenance

Maintenance Planning

Create

Single Cycle Plan

(IP41)

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Select the transaction and Double click or

press Enter Key

to reach the

following screen


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Field name


Required


/ Optional Maintenance

Plan R

Category

Choose

the

Maintenance

Plan

Category:

“Maintenance Order”

Press Enter to get the following screen

In the screen, enter the values in the following fields:

Field name

Required


/ Optional Maintenance

plan R

Enter

appropriate

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description

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Required

Field name


/ Optional description

maintenance plan. Ex: “Periodic shutdown plan for BI/BWM/01 SOP:BI0003”

Cycle/unit

R

The maintenance period and the unit of period should be entered. Ex: 2 mon, 30 day etc.

Cycle text

O

Enter proper text to describe the cycle duration.

Offset/unit

O

The time period by which the first scheduled call object should be postponed.

Counter

O

If the maintenance activity is performance based, counter should be used. Example “Number of operations/hrs a motor is run” etc.

Reference

object: O/R

Reference object on which the maintenance

Functional Location

activity should be carried out.

Reference

Reference object on which the maintenance

object: O/R

Equipment

activity should be carried out. After selecting equip press enter key so that system selects data from master

Planning plant

R

Planning plant

Order type

R

Enter maintenance order type: Ex: PM02 on which the maintenance call objects will be created.

Main Work Center

R

Main Work Center

Business Area

R

Business Area

Task list

O

Assign a task list either general, equipment of

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Field name


Required


/ Optional functional location task list.

Click on icon

to reach the following screen

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In the screen, enter the values in the following fields:

Required

Field name


/ Optional Call horizon

O

%

of

scheduling

period

that

should

be

considered in planning. If nothing is mentioned 100% will be considered. Scheduling period

O

Planning period during which call objects will be created as per the cycle duration”.

Start of cycle

O

Enter the date on which the planning cycle should start.

Scheduling

O

indicator

If a day of a month is critical and cycle period is in months choose Time-key date other wise choose Time. If only the working days are to be considered, choose time-factory calendar.

Equipments

O

New equipments or functional locations that are to be added in the same plan should be created and added in the same plan.

Completion

O

requirement

If the fresh maintenance order to be created by the system after successful completion of the previous

maintenance

order,

then

check

completion requirement check box.

In item overview all the maintenance items that are considered in the current plan are displayed. To add a counter for performance based preventive maintenance: Last changed on:

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Enter required counter no. in “Counter” Field (Counter no. can also be searched using icon

)

After entering all the planning data click on

to save the plan

3.10 Maintenance Plan Scheduling Maintenance Schedulin g:

Scheduling for maintenance jobs as per prepared maintenance plans During a schedule run, system schedules the planned dates and the call dates Call date is the advance date of order generation by the system (as defined in maintenance scheduling parameters) to facilitate maintenance planner to arrange for execution of maintenance activity on planned date. The call date is the date on which a maintenance order is created in the system. This is determined by the call horizon of the maintenance plan.

Trigger: To schedule the maintenance plan and monitor its progress, including making scheduling modifications as necessary.

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Business Process Procedure Overview Maintenance plans in SAP are designed to automatically generate calls for orders, notifications, or service requests when the parameters attached to the item are met. When an order is created, a request for the resources outlined in the order is made. However, they are not reserved until the order is released. Once released an order may have goods, labor, and services charged to it. Releasing a work order gives the others the authority to reserve its resources, purchase additional ones, and start charging costs. If you decide not to do this work you can release and technically complete the order immediately.

Note: The plan is constantly adjusting itself to keep consistent with the cycle lengths linked to the items. Thus, each time a call is closed outside the cycle length and the associated tolerances, the plan is adjusted accordingly. If this is a recurring practice, future planned call dates will be fluctuate sporadically and could be difficult to keep track of.

Output – Results

Comments

A view of the scheduled calls for a maintenance plan

ID: PM

Title: PREVENTIVE MAINTENANCE –MAINTENANCE PLANNING

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Business process: Transaction IP10


Maintenance Scheduling

code: Menu

path:

Logistics

Preventive maintenance

Plant

maintenance

Maintenance Planning

Scheduling for Maintenance Plans

Schedule

(IP10)

Select the transaction and Double click or press Enter Key to reach the following screen

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In the initial screen, enter the values in the following fields: Required

Field name


/ Optional Maintenance Plan

R

Press Enter key Enter key or click on

Select the Maintenance Plan from the list

Enter / Continue icon to get the following screen

and then Click on the “Start” or the “start in cycle” cycle” Push button as per Requirement. Requirement.

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The plan is ready for a schedule run. Press start button start button to Run Scheduling from the Start. If you want to Start the Plan from within the Cycle then one needs to use “Start in Cycle‟.

Use

“Start”

when

Use “Start in Cycle”

you need to start the Plan from the Start of the Cycle.

when you need to start the Plan from with in the cycle.

The Following Screen appears.

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Click on “Scheduling

Overview.

The scheduled call call object will be displayed displayed as above. If the overview list list is to be analyzed click on Scheduling overview list. Release the scheduled plan for creating the maintenance orders. The Overview will appear as below

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For list displays of schedule plans and call objects:

Use the following transactions for various list displays;

Trigger: To list the scheduled calls for a maintenance plan or group of plans

Business Process Procedure Overview To view the scheduled calls for a maintenance plan in a list format

Output – Output – Results Results

Comments

List of scheduled calls for review

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For viewing plan / execution status select transaction IP24 and press Enter key to reach the Following screen

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Select by maint plan category as PM (or use the available fields for different search criteria)

click on

to view the following screen

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Calibration process is as same as Preventive maintenance in PDIL Case. So Kindly follow the same Process.( Only maintenane Order type, Planner Group, Work Center will be changed as per the Calibration)

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4. Maintenance Processing 4.1 Measuring documents Measurement readings are to be taken at measuring points in particular measurement units at particular intervals. (For example, the feed water temperature in degrees Celsius of the boiler daily at 6.00 am) Measurement readings describe a condition at a measuring point at a particular point in time, and represent the transaction data for measuring points in the MY SAP ERP System. They are documented in the form of measurement documents. An optimum value for a particular measuring point to which the device concerned is calibrated can be maintained as a target value for the measuring point.

Creation of Measuring Document: Measuring documents can be created for Functional location & equipment measuring points.

Trigger: A measurement or counter reading from a measurement point needs to be entered into the system.

Business Process Procedure Overview After a measurement has been taken at a measuring point or a counter, the data needs to be entered into the system. A measurement document comprises the data entered in the system

Output - Results

Comments

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Measurement Document

Document may be verified by running transaction IK13

created

(display measurement document). Refer to business process procedure „Display Measurement Document‟ to verify results.

Case 1 : Normal Measuring Point

Transaction IK11

code: Menu

path:

Management

Logistics of

Technical

location/equipment

Plant

maintenance

Objects

functional

measuring document

create

(IK11).


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Required

Field name


/ Optional Measurement point

R

Select the measuring point on which the measuring point to be entered

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Required

Field name


/ Optional

Measurement time

R

Enter date & time when measurement is taken

by

R

Enter the name of person who has taken reading .

Press Enter Key

Case 1- if the measuring point is a counter following screen will appear as below

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Field name


/ Optional Counter reading

R

Either counter or difference reading has to be entered to calculate the second parameter Enter the display reading of counter if the physical counter is maintained press enter to calculate difference of reading in the system

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Required

Field name


/ Optional Counter reading

R

Either counter or difference reading has to be entered to calculate the second parameter Enter the display reading of counter if the physical counter is maintained press enter to calculate difference of reading in the system

difference

Either counter or difference reading has to be

R

entered to calculate the second parameter Enter the difference of reading & press enter the system will calculate counter reading

Click on

to save the readings

Case 2- if the measuring point is not a counter following screen will appear

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Screen fields data entry instruction:

Field name

Required


/ Optional Meas rdg

Click on

R

Enter the reading of measurement

to save the readings

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MEA SURING POINT ENTRY LIST

Trigger: A measurement or counter reading from a measurement point needs to be entered into the system.

Business Process Procedure Overview After a measurement has been taken at a measuring point or a counter, the data needs to be entered into the system. A measurement document comprises the data entered in the system

Output - Results

Comments

Measurement Document

Document may be verified by running transaction IK13

created

(display measurement document). Refer to business process procedure „Display Measurement Document‟ to verify results.

Creating Entry List Transaction IK31

code: Menu

path:

Logistics

Plant

maintenance

Management of Technical Objects

Environment

measuring points

measuring reading entry list

(IK31).

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Type entry list name

Type entry list name & press Enter key or click on


To reach the following screen

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Required

Field name


/ Optional MeasPoint/ Counter

R

Select the measuring point on which the measuring point to be entered

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Required

Field name


/ Optional

Measu point

short R

System defaults from master data

O

System defaults from master data

text Meas Position

Click on

Following message will appear on the screen

Measur ement reading s entry throug h Measur ement reading s Entry List

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Transaction IK34


code: Menu

path:

Logistics

maintenance Maintenance completion documents

confirmation collective entry

Plant Processing measurement with entry list

(IK34).

Press Enter Key or Double click on selection To reach the following screen

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In the initial screen, enter the values in the following fields: Required

Field name


/ Optional Entry list

R

Enter the entry list number or select from the drop down list

Measurement time

R

Enter date & time when measurement is taken

Read by

R

Enter the name of person who has taken reading.

Press Enter Key or Click on tab

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Reading/Counter

Required

reading

/ Optional

For measuring point enter read value or For counter either counter reading or difference reading has to be entered to calculate the second parameter by the system

(Enter the display reading of counter if the physical counter is maintained press enter to calculate difference of reading in the system) Difference

(for R

counters)

Either counter or difference reading has to be

entered

to

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the

second

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Reading/Counter

Required

reading

/ Optional

For measuring point enter read value or For counter either counter reading or difference reading has to be entered to calculate the second parameter by the system

(Enter the display reading of counter if the physical counter is maintained press enter to calculate difference of reading in the system) parameter Enter the difference of reading & press enter the system will calculate counter reading

Click on

to save the data

Notifications Notification is a means, by which internal company notifications like equipment malfunctions; breakdowns, maintenance requests or activity reports etc are entered and managed in Plant Maintenance. Notifications can be created on Equipment and Functional locations.

Trigger: An internal problem or maintenance request needs to be logged for problem reporting and technical resolution. Last changed on:

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Business Process Procedure Overview This document describes how to create a PM notification for any notification type. A notification is used to capture technical information and assign tasks that do not involve the tracking of costs. The user can create a maintenance order or a quality notification from the PM notification. Note: With this transaction, the screen layout will differ based on the notification type as defined in customizing. Refer to Business Procedure document for Create Maintenance Request, Create PM Malfunction Report and Create PM Activity Report.

Output – Results

Comments

Creation of a notification

Refer to Business Process Procedure „Display PM Notification', to verify this result.

ID: PM

Title: CREATING NOTIFICATION

Business process:

6.4.3.1 - Maintenance Processing - Notifications

Transaction

code: Menu

IW21

path:

Logistics

Maintenance Processing

Plant

maintenance

Notification

create

(IW21)

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Use this transaction for creating Notifications on Functional Locations and Equipment.

As technical objects like buildings are installed as Functional locations, all jobs that are required to be carried for buildings are to be created on Functional Locations.

Maintenance Request (M1) Maintenance requests are notifications used to request the maintenance department to perform an activity. Unlike malfunctions reports, maintenance requests are not used in the event of malfunctions. They are typically used in conjunction with investments, reconstruction or replacement.

Malfunction Report (M2) A malfunction report describes a malfunction of an object, which restricts the performance of that object in some way. A user can use a malfunction report to inform the maintenance department that a system is not functioning correctly, is not Last changed on:

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working at all, or is producing poor results. Malfunction reports are intended to prompt the maintenance department to carry out a maintenance task to restore the target condition of the object.

Activity Report (M3) An activity report describes a maintenance activity that has already been carried out and was not necessitated by a malfunction, problem or damage. An activity report is a technical document and is used to verify which activities were carried out when, and for what reason, as well as the result of these activities. Typical examples of activity reports include inspection or maintenance findings. These documents all the results of an inspection, or the technical values of an object determined during or after regular preventive maintenance work. Inspection tasks are not requested explicitly via a malfunction report and are usually based on inspection orders. Preventive maintenance work is carried out to preserve the target condition of the object, and is based on preventive maintenance plans.

IT Report (IT) An IT report describes a malfunction of an object, which restricts the performance of that object in some way. A user can use a malfunction report to inform the maintenance department that a system is not functioning correctly, is not working at all, or is producing poor results. Malfunction reports are intended to prompt the maintenance department to carry out a maintenance task to restore the target condition of the object.

After selecting the transaction, press Enter key or double click to reach the following screen

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In the Initial screen , you can select the type of Notification and press ENTER key or click on

Enter / Continue icon to reach the next screen

Type Of Notification:

Maintenance Orders To carry out internal maintenance jobs or external services as per the maintenance requests or according to day to day observations and for preventive maintenance activities, a

maintenance order is to be prepared to plan for material, manpower

and services requirement. On the basis of maintenance orders only, maintenance jobs costing, reservation for material and manpower planning can be done. Maintenance Orders are to be created by Maintenance dept on: Last changed on:

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Functional Locations Equipments

Maintenance Orders can be created against: Notifications Direct/Adhoc

Maintenance plans (thro. maintenance plans and schedules)

Maintenance Orders are to be created on the following conditions: When a material is to be drawn from the storage location When External Services are required. When history of activities are need to be captured.

The different types of Maintenance Orders configured in the system are as follows:

Type

Description

PM01

Breakdown/malfunction maintenance order

PM02

Preventive Maintenance order

PM05

Calibration order

PM07

Regular Maintenance

Please use appropriate type of order, for capturing the data under various categories.

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As technical objects like buildings are installed as Functional locations, for jobs that are required to be carried out, Maintenance orders are to be created on Functional Locations.

4.2 Breakdown Maintenance Process: Malfunction Report (M2) A malfunction report describes a malfunction of an object, which restricts the performance of that object in some way. A user can use a malfunction report to inform the maintenance department that a system is not functioning correctly, is not working at all, or is producing poor results. Malfunction reports are intended to prompt the maintenance department to carry out a maintenance task to restore the target condition of the object.

i) Create Notification for reporting Machinery malfunctions/Breakdown (M2)

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>Fill the Description of the Problem

>Fill/Select Functional location & Equipment

>Fill the Reported BY

>Press ENTER

>WE find this screen which show last 3 activities status on that particular equipment

Notification Header

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Click ENTER

/

Press

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Notification Description

>For M2 type Notification >we have to click in box of Breakdown > In this screen we can correct the date/time of Malfunctioning start >Click/Press ENTER

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Here we can see Warranty Status of Equipment

Long Text Can be Written at this place

Required

Field name


/ Optional Notification

R

Description of activity to be carried out

Description Functional location/ O

Select from the List of Equipment.

Equipment Required start

O

System copies the present date, a different date and time also can be entered, as required.

Priority

O

Select the priority as required

Required End

O

Enter the date and time on which the job to be completed

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Required

Field name


/ Optional Planner group

O

Planner

groups

as

per

the

maintenance


work O

center

Maintenance work center, currently represents the departments

Reported by

R

Mention

the

Name

of

the

Person,

for

identification Purpose Malfunction start

O

Time of Malfunction

Malfunction end

O

Time of end of malfunction.

Cause text

O

Give reason for failure

Long text

O

Mention required details

IMPORTANT : If it is a Breakdown, checkbox „Breakdown to be selected.

After entering all the required values, click on

to

save

the

Notification.

i i ) N o t i f i c at i o n Pr o c e s s i n g

Initially Notification will have the status “OSNO” when it is created, Notification is to be released for changing the status as “NOPR” and after completing the notification, status will change to “NOCO”, if any order is assigned to this notification, status “ORAS” will be there.

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After entering all the required values, click on

to

save

the

Notification. And following message will appear on the screen

If NO cost is involve we can document all work in Notification Only.There is no need to create Maintenance Order.

Notification – Put in process :

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Check for status change from OSNO to NOPR

i i i ) No t i f i c a t i o n C o m p l e t i o n

Notification is to be selected by using transaction codes IW22 / IW28 to reach the following screen

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Enter the notification number in Notification box or select from the list Press Enter key or click on “Notification” to reach the following screen Click completion flag to get the completion screen

Enter completion details as explained in following table

Required

Field name


/ Optional Malfunction start

R

Time of malfunction begin

Malfunction end

R

Time of end of malfunction

Complete the notification by clicking on

Complete Flag.

Observe status change from NOPR to NOCO (Notification completion.)

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The Notification is completed, If the activity is unsatisfactory, the notification can again be opened and again put into operation.

With reference to this notification, If Maintenance order is to be created for carrying out the above work,

then click on

create Icon.

Click here

Or go to menu path PM Notification -> Order -> Create -> Direct as shown in the following screen

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You will reach the following screen

Enter / check Order Type, Main work center and click on

Enter / Continue

icon To reach the following screen

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For planning in terms of manpower and material and for further processing of order,

After entering required details, save the order and following message will appear on the screen.

iv) Maintenance Order Creation/Change

Trigger: Internal work hours and costs need to be captured and transferred to other cost objects for maintenance / service work. Last changed on:

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Business Process Procedure Overview A detailed work planning document which holds details on resources, components, costs, and labor required to complete specific maintenance work. Can be created with or without a notification. The costs are settled to other cost objects, such as cost center.

Output - Results

Comments

Creation of a PM Order

Refer to Business Process Procedure „Display PM Order to verify this result

Observe the system status, during creation and order processing : CRTD - Order created Last changed on:

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MANC - Material availability not checked NTUP - Dates Not updated NMAT - No Material components PRC - Order Precosted SETC - Settlement Rule created TECO - Technical Completion CNF - Complete confirmation REL

- Order released

CLSD - Order Closed PCNF - Partial confirmation

Enter the field values in different tabs like

as explained in following table

Required

Field name


/ Optional Header data : Planner Group

O

Default is copied from the system by Master data

Maint .work center

R

Default is copied from the Equipment, but it can be changed , if required. This is required for tracking purpose.

Costs

O

The approx. cost can be given

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Required

Field name


/ Optional PM Activity type

O

Activity type can be selected from the drop down list.

System condition

O

This activity is to be carried out when the Equipment/System is

in operation or to be

stopped Basic start

O

Enter the proposed date of start

Basic Finish

O

Enter the proposed date of end

Priority

O

Copied form the system, if already given.

Revision

O

Revision is to be selected form the drop down list (Pl see the Notes.#1)

Reference object

R

The functional location or Equipment is copied form the initial screen

First Operation Operation

R

Name of the operation

Work Center

R

Work center

Control key

R

To be mentioned whether „PM01‟ or „PM03‟ – PM01 indicates the job to be done internally,

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Required

Field name


/ Optional PM03 - if the job to be carried out externally

Work

duration, O

Depending on the calculation key, enter any 2

Number, Operation

or 3 values, so that the 3rd value will be

duration

calculated automatically / manually.

Calculation key

O

Select from the drop down list

Notes:



If the operations are more than one operation, use the operation tab strip, and enter as many operations as required.



The work centers for different operations can be different. (If required).



Control Key PM01 Denotes – Work done by Own Employee & PM03 denotes work done by External Vendor. For PM03 Purchase Requisition will be created automatically. Which will go for Release Process & then Purchase

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Order will be created.This is MM Module Process, can be viewd in MM User Manual.

Fill the Material Group,Purchasing Group,Requisitioner name,Tracking No. Then Click on this

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Purchase Requisition Number Genrated.

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Required

Field name


/ Optional Component

R

Indicate Material code of the component.

Requirement Qty

O

Indicate the quantity of the components

Description

and O

Automatically copied from the system.

UM I Category

R

Indicate whether it is stockable or Nonstockable, „L‟ or „N‟

S LOC

O

Stock can be checked thro. this.

Notes : Item category - significance of „L‟ and „N‟ .

L – Generally stockable item, when a component is

selected „L‟

-

a

reservation is created .

Reservation creation is irrespective of material stock. (Means, even if the material is not available in the storage Location, reservation will be created.).

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N – means Non-stockable, but coded item. – Even if stock is available , „N‟ can be indicated. The system will create a PR for the Items for which „N‟ is indicated.

Reservation Number Generated for Stock Item. Material Issue against Reservation process can be viewd in MM End User Manual as it is MM Process.

Click on

to save the Order

v) PROCESSING THE ORDER 1.RELEASING THE ORDER

ORDER CAN BE RELEASED WHILE CREATING OR AFTER CREATION ALSO. RELEASING WHILE CREATING Last changed on:

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CLICK ON RELEASE FLAG

, THE SYSTEM STATUS WILL CHANGE

FROM “CRTD” TO “REL”

RELEASE FLAG

RELEASING AFTER CREATION and then SAVE the Order.

SELECT THE ORDER WHICH IS TO BE RELEASED BY TRANS CODE “IW32”

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ENTER THE ORDER NO OR SELECT FROM THE DROP DOWN LIST

Select the Release Button

to release the order

The order will be released., Check status as below..

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Check for status changed to REL

v) COMPLETION CONFIRMATION

A.TIME CONFIRMATION Trigger: Actual hours worked and materials used need to be recorded and posted to the PM order. Business Process Procedure Overview The actual hours worked per operation are recorded/posted to the PM/CS order via time confirmation. Any materials used may be posted at this time. Technical reporting to the notification may also be performed at this time.

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Output – Results

Comments

Time confirmed to PM order

Refer to Business Process Procedure 'Display PM Order' (and view cost report) or 'Display PM Order Confirmation' to verify results. The document flow on the PM order will also show any time confirmations posted.

Press Enter key or double click (with mouse Left key) to reach the following screen;

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ENTER ORDER NO SELECT FROM LIST

OR

PRESS ENTER KEY TO REACH THE FOLLOWING SCREEN SELECT THE OPERATIONS TO BE CONFIRMED AND FOLLOW THE MENU PATH SHOWN IN THE NEXT SCREEN

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DOUBLE CLICK ON THE ACTUAL DATA FOLLOWING SCREEN WILL APPEAR Last changed on:

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FOR NEXT OPERATION

ENTER THE OPERATION ENTER THE START & END DATE WITH TIME CONFIRM ACTUAL MAN HOURS IF WE ARE DOING FINAL CONFIRMATION SELECT THE FINAL CONFIRMATION BOX CLICK ON CLEAR OPEN RES. IF NO MORE MATERIALS ARE REQUIRED AGAINST THE RESERVATION. RESERVATION. IF THERE IS NO REMAINING JOBS TICK THE NO REMAIN WORK BOX CLICK ON RIGHT ARROW KEY FOR NEXT OPERATION SAVE THE CONFIRMATION BY CLICKING ON

AND FOLLOWING MESSAGE WILL APPEAR ON THE SCREEN

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vi) SERVICE ENTRY SHEET SERVICE ENTRY SHEET HAS TO BE FILLED FOR CLEARING THE INVOICE.

Trigger: Requirement for recording services performed by service provider

Business Process Description Overview This document document describes the procedure for creating a service entry sheet.

Within

purchasing, this service entry sheet document is designed for the recording of the services that have been been performed by the service service provider. The service entry sheet is a list of all planned services services that have actually been performed. performed. It can also be used used to lust and specify unplanned services that have been performed and whose precise scope and nature were unknown at time of planning phase.

Output – Output – Results Results

Comments

Service Entry Sheet

Menu Path

Via Menus

Logistics> Plant Maintenance> Maintenance Processing> Completion Confirmation> Services

Via Transaction Code

ML81n

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or use transaction transaction code “ML81N” to reach the following following screen

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select Purchase order number as shown in next screen

click on the


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Click on This tab service entry sheet

create

Click on the service selection tab

SERVICE SELECTION TAB

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Following screen will appear

Following screen will appear

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Click here

then click on Services Push button

Click to line item

Select

The following screen will appear ACCEPTING SERVICE ENTRY SHEET Last changed on:

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3. Click on this flag for accepting

2.

Service Entry sheet Number

2. Confirm the required quantity

Click on the green flag for accepting the services. Save the transaction clicking save button

Following message will appear

B.GOODS ISSUE Part will be taken care in MM User manual.

vii)

ORDER TECHNICAL COMPLETION

SELECT THE ORDER FROM MENU PATH

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Complete the order by clicking on

Complete Flag.

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PLANT MAINTENANCE ECC 6.0 RAVINDER KUMAR 23 Click Nov‟10 on Tech.

Completion flag

WHILE COMPLETING TECHNICALLY SYSTEM DEFAULTS CURRENT DATE & TIME BUT STILL IT CAN BE CHANGED FOR PAST CONFIRMATIONS

Check status – TECO

viii) Order Settlement Order settlement is used to control costs and to identify where maximum costs are being incurred for maintenance. Costs associated with the maintenance work are assigned to Cost centres. Costs arising out of executing an order are initially collected on the order. These costs are then transferred to a receiver, for e.g. Cost centre. The receiver of costs are specified in the order and settlement carried out at regular intervals by FI.

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ix) Business Completion The business completion of an order is usually performed when no further costs are expected to be posted to the order. An order can only have business completion when: It has been technically completed It has been settled and the order balance is 0 No outstanding purchase orders (commitments) exist for it All data that refers to the reference object of the maintenance order is available and correct All relevant data in the operations and sub-operations is available and correct The business completion function for an order defines the following information for the order: The order obtains the status Completed. It is indicated as fully completed. The order cannot receive any more postings, even for posting of costs. It is locked for all collective-processing changes. Business completion can be performed for An individual order Several orders using collective processing Business completion of the order can also be cancelled.

4.3 Preventive Maintenance To ensure higher equipment availability and reliability, preventive maintenance plans are required for critical equipments and systems. The preventive maintenance plans can generate PM order/Notification /service Entry Sheet as per the pre-defined schedules, based on time elapsed or any other Last changed on:

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performance criteria.

i) Maintenance task lists Maintenance task lists describe a sequence of individual maintenance activities, which must be performed repeatedly within a company. In PDIL we are using only one maintenance task list: i.e. General Maintenance Task List Tcode :IA05

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ii) Maintenance Plan Maintenance plan describes the maintenance and inspection tasks to be performed at maintenance objects with the dates and scope of the tasks.

Time-Based maintenance Plans In time-based maintenance planning maintenance is performed in specific cycles, for example, every two months or every six months.

Maintenance Planning: Last changed on:

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Maintenance planning is done to describe the dates and scope of corrective maintenance and inspection activities at technical objects. This ensures that the technical objects are maintained on time and thereby function optimally.

Based on analysis by the maintenance personnel, equipments are identified, where planned maintenance needs to be carried out.

Apart from the experience,

maintenance person may refer manufactures‟ recommendations and the history of the equipment to define the basis.

The maintenance planner also needs to identify the units for the maintenance plans time (weekly, monthly, yearly, etc.) or performance (every 100 running hours, every 10,000 shots etc.). For performance based maintenance plans, relevant measuring counter needs to be defined for the technical object and measurement readings need to be updated regularly.

The maintenance planner decides the maintenance call objects for the plan. The call object can be maintenance order, notification or service entry sheet. Based on the selection, system generates a call object for a maintenance plan, when a maintenance call is due. The maintenance planner decides initially which call object is required.

As mentioned earlier, maintenance plans can be single cycle, strategy based or multiple counters, as per the requirement of each equipment / functional location.

Maintenance task lists shall be prepared for equipments / functional location, as per the requirement. The task lists contains detailed sequence of activities to be performed, spares and estimated time required for completing the job. Last changed on:

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For the activities, which are common amongst group of equipments, a general task list may be prepared.

A maintenance plan includes the task list, maintenance strategy along with other scheduling parameters.

Tcode :IP01

Fill here maintenance plan category- Maintenance Order.

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Fill the maintenance plan cycle with its unit i.e. when we require the Maintenance order to be generated. As we select yearly cycle then the order will generate every year.

Here fill the detail of maintenance item on which the Maintenance Order will generate.

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Here fill the detail of calibration task list. As its type & its no.

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Call horizon – here fill percentage when the call to be come for maintenance. Exp.If cycle = 100 days, & call horizon =90%, means at 90th day we will receive the order, for planning the man & material required to complete the maintenance order. Scheduling Period Now we fill the maintenance plan scheduling parameters i.e. the time for which we will schedule this plan. If we take sch. Period 10 year then total 10 Nos. maintenance orders will generate with yearly cycle.

iii) Maintenance Plan Scheduling Once the maintenance plans are created, then these plans are scheduled.

It is

important to input “Start date” or “Starting counter reading” in the individual maintenance plan. This date or counter reading decides the schedule dates.

Scheduling can be done manually as well as by system. It is recommended to do the scheduling by system to avoid manual errors.

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or service entry sheet depending on definition of the call object of the plan.

The maintenance planner shall schedule the maintenance plan. Before the call objects are created by the system, maintenance planner may manually call the job or skip the job, depending on the situation.

If the call object is a maintenance order, then maintenance planner shall release it manually after checking the order.

There is provision in the system to shift the next scheduled maintenance date of a maintenance plan, if there is considerable delay in completing the order or the orders are completed much ahead of the schedule. These tolerance ranges for shifting can be decided while defining maintenance plan by the maintenance planner depending on the nature of the job.

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Tcode:IP10

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Tcode : IW39

iv) Maintenance Order Processing The maintenance order is a detailed planning assistance for maintenance tasks to be performed. The order is used to: 

Add tasks (if required) in Task List attached in Preventive Maintenance Order with detail regard to type, scope, dates and resources



Monitor the execution of tasks (operations)



Define rules for account assignment, settlement and budgets



Enter, assign and settle the costs which arise from tasks

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The order can be processed internally by own employees, or can be processed externally, that is, assign it to another company for processing. An order consists of: 

Order header



Object list

Operations





Material list



Settlement rule

Costs



Observe the system status, during creation and order processing : CRTD - Order created MANC - Material availability not checked NTUP - Dates Not updated NMAT - No Material components PRC - Order Precosted SETC - Settlement Rule created TECO - Technical Completion CNF - Complete confirmation REL

- Order released

CLSD - Order Closed PCNF - Partial confirmation

Order Release

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Preventive Maintenance orders will be already released. If order has been released and subsequently additional operations are entered for it, these are automatically released. Following activities can only be performed when order is released: 

Printing shop papers



Withdrawing material



Posting goods receipts



Entering time completion confirmations

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Tcode:IW32

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Fill the Material Group,Purchasing Group,Requisitioner Group,Requisitioner name,Tracking No. Then Click on this

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Fill the various components /spares with No. (From component list) & quantity required for completing the work.

Notes :

Item category - significance of „L‟ and „N‟ .

L – Generally stockable item, when a component is

selected selected „L‟

-

a

reservation is created .

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storage Location, reservation will be created.).

N – means – means Non-stockable, but coded item. – item. – Even if stock is available , „N‟ can be indicated. The system will create a PR for the Items for which „N‟ is indicated.

Reservation Number Generated for Stock Item. Material Issue against Reservation process can be viewd in MM End User Manual as it is MM Process.

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Required

Field name


/ Optional Component

R

Indicate Material code of the component.

Requirement Qty

O

Indicate the quantity of the components

Description

and O

Automatically copied from the system.

UM I Category

R

Indicate whether it is stockable or Nonstockable, „L‟ or „N‟

S LOC

O

Stock can be checked thro. this.

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Change of Purchase Requisition (Tcode : ME52N)

We Need to fill the DOP Clause & Pre Qualification for each PR.

Creation of PO & Material Issue is covered under MM Module.

v) SERVICE ENTRY SHEET SERVICE ENTRY SHEET HAS TO BE FILLED FOR CLEARING THE INVOICE.

Trigger: Requirement for recording services performed by service provider

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Business Process Description Overview This document describes the procedure for creating a service entry sheet.

Within

purchasing, this service entry sheet document is designed for the recording of the services that have been performed by the service provider. The service entry sheet is a list of all planned services that have actually been performed. It can also be used to lust and specify unplanned services that have been performed and whose precise scope and nature were unknown at time of planning phase.

Output – Results

Comments

Service Entry Sheet

Menu Path

Via Menus

Logistics> Plant Maintenance> Maintenance Processing> Completion Confirmation> Services


ML81n

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or use transaction code “ML81N” to reach the following screen

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Click

select Purchase order number as shown in next screen

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click on the



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Click on the service selection tab

SERVICE SELECTION TAB

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then click on Services Push button

Click to line item

Select

The following screen will appear ACCEPTING SERVICE ENTRY SHEET

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1.

Service Entry sheet Number

2. Confirm the required quantity

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Only Authorized person can release the Service Entry Sheet.

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3. Save

Tcode ML85 or ML81n Can be used to release the Service Entry Sheet with proper autherization.

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Fill the code & Group Execute

release release then

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2. Release

1.Select the Line

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Released Saved

vi) COMPLETION CONFIRMATION

A.TIME CONFIRMATION

Trigger: Actual hours worked and materials used need to be recorded and posted to the PM order.

Business Process Procedure Overview The actual hours worked per operation are recorded/posted to the PM/CS order via time confirmation. Any materials used may be posted at this time. Technical reporting to the notification may also be performed at this time.

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Output – Results

Comments

Time confirmed to PM order

Refer to Business Process Procedure 'Display PM Order' (and view cost report) or 'Display PM Order Confirmation' to verify results. The document flow on the PM order will also show any time confirmations posted.

Press Enter key or double click (with mouse Left key) to reach the following screen;

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ENTER ORDER NO SELECT FROM LIST

OR

PRESS ENTER KEY TO REACH THE FOLLOWING SCREEN

SELECT THE OPERATIONS TO BE CONFIRMED

AND FOLLOW THE MENU PATH SHOWN IN THE NEXT SCREEN

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CLICK ON THE ACTUAL DATA FOLLOWING SCREEN WILL APPEAR

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FOR NEXT OPERATION

ENTER THE OPERATION ENTER THE START & END DATE WITH TIME CONFIRM ACTUAL MAN HOURS IF WE ARE DOING FINAL CONFIRMATION SELECT THE FINAL CONFIRMATION BOX CLICK ON CLEAR OPEN RES. IF NO MORE MATERIALS ARE REQUIRED AGAINST THE RESERVATION. IF THERE IS NO REMAINING JOBS TICK THE NO REMAIN WORK BOX CLICK ON RIGHT ARROW KEY FOR NEXT OPERATION SAVE THE CONFIRMATION BY CLICKING ON

AND FOLLOWING MESSAGE WILL APPEAR ON THE SCREEN

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vii)


ORDER TECHNICAL COMPLETION

SELECT THE ORDER FROM MENU PATH

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Complete the order by clicking on

Complete Flag

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WHILE COMPLETING TECHNICALLY SYSTEM DEFAULTS CURRENT DATE & TIME BUT STILL IT CAN BE CHANGED FOR PAST CONFIRMATIONS

Check status – TECO

viii) Order Settlement Order settlement is used to control costs and to identify where maximum costs are being incurred for maintenance. Costs associated with the maintenance work are assigned to Cost centres. Costs arising out of executing an order are initially collected on the order. These costs are then transferred to a receiver, for e.g. Cost centre. The receiver of costs are specified in the order and settlement carried out at regular intervals by FI.

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ix) Business Completion The business completion of an order is usually performed when no further costs are expected to be posted to the order. An order can only have business completion when: It has been technically completed It has been settled and the order balance is 0 No outstanding purchase orders (commitments) exist for it All data that refers to the reference object of the maintenance order is available and correct All relevant data in the operations and sub-operations is available and correct The business completion function for an order defines the following information for the order: The order obtains the status Completed. It is indicated as fully completed. The order cannot receive any more postings, even for posting of costs. It is locked for all collective-processing changes. Business completion can be performed for An individual order Several orders using collective processing Business completion of the order can also be cancelled.

4.4 Regular Maintenance : i) Notification Creation: Notification for new Requirement/or any kind of Modification request.

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>Fill the Description of the Request/Modification

>Fill/Select Functional location & Equipment

>Fill the Reported BY

>Press ENTER

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Click ENTER

/

Press

>WE find this screen which show last 3 activities status on that particular equipment & then Save notification.

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Notification number generated. You can see the list of Notifications through Tcode :IW29

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Select the Desired Notification & create the Regular maintenance Order (Type:PM07).

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ii) Maintenance Order Do your Planning in Regular Maintenance Order. Tcode:IW32

After that whole Process is same as Breakdown Maintenance Process. So Kindly follow the Breakdown process( mentioned Above).

4.5 Calibration Process: Test equipment is used for performing quality inspections. In order to ensure that the test equipment used always fulfils the defined performance criteria, we have to regularly test and calibrate these test equipment. Using the functions in the component Test Equipment Management, we can manage equipment data, plan and schedule inspections, and perform calibration inspections for the equipment. Last changed on:

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i) Task List for Calibration Calibration task lists describe a sequence of individual calibration activities, which must be performed repeatedly within a company. Creation of Task List

Transaction code – IA05

Fill the External AlphaNumeric Number for Calibration TaskList & the in Profile fill -PDIL And press enter.

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Fill the header data for the Calibration task list. As Usage-4, Status-4, System condition-0, Work Center, planner Goup And Now click on operations.

Fill the operations required to carry out the calibration process with estimated time & manpower required.

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Calibration Task list is saved with number generated.

ii) Creation of Calibration Plan Tcode :IP01

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Fill here maintenance plan category- Maintenance Order.

Fill the maintenance plan cycle with its unit i.e. when we require the Maintenance order to be generated. As we select yearly cycle then the order will generate every year.

Here fill the detail of maintenance item on which the Maintenance Order will generate.

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Here fill the detail of maintenance item on which the Maintenance Order will generate. Order Type of Calibration Order should be PM05.

Here fill the detail of calibration task list. As its type & its no.

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Call horizon – here fill percentage when the call to be come for maintenance. Exp.If cycle = 100 days, & call horizon =90%, means at 90 th day we will receive the order, for planning the man & material required to complete the maintenance order. Now we fill the maintenance plan scheduling parameters i.e. the time for which we will schedule this plan. If we take sch. Period 10 year then total 10 Nos. maintenance orders will generate with yearly cycle.

Now save the maintenance plan. Number displays here.

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After Wards Calibration Process is same as Prevntive Maintenance. So Kindly Follow Preventive Maintenance Cycle.

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5. Plant Maintenance Information System 5.1 Standard Reports There are so many Standard Reports in PM.

Some of the UseFul reports are shown below:

Transactio n c od e : IK17

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Trigger: Need to display measurement documents with similar characteristics.

Business Process Procedure Overview Search for measurement documents by various search criteria to compile a list of measurement documents to display. You may search for a measurement document whose number is unknown or perform collective processing for measurement documents that have particular characteristics in common.

Output – Results

Comments

One or many measurement documents selected for display Input – Required Fields

Field Value/Comments

Procedural Steps Via Menus

Logistics

 Plant

Maintenance  Maintenance

Processing  Completion Confirmation  Measurement Document


 List

Editing

 Display

IK17

Select the transaction as shown in following screen

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on double click you will reach the following screen

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Input data for selection , you can get the report based on the input data like Measuring points Equipment Functional location etc., After the entry of required data click on to execute the transaction and you will get the following report

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Spares and consumables consumption Report Transactio n co de : MB51

Trigger: User wishes to search for material movements by material.

Business Process Description Overview This process describes the method to search for and display the material movements by material.

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Output – Results

Comments

Materials with the associated movement types.


(a) Logistics > Materials Management > Inventory Management > Environment > List Displays > Material Documents Logistics > Materials Management > Physical Inventory >Environment > Mat. Doc. For Material


MB51

Select the transaction as shown in following screen

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on double click you will reach the following screen

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Enter required data like Plant, Storage Location, Movement type etc., as per your report requirement After the entry of required data click on to execute the transaction and you will get the following report

Report of spares consumption against Maintenance Orders T r an s a c t i o n c o d e : I W 3M

Reach the selection screen with help of following menu

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Selection screen

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Enter required selection filed values like Order no, Material, storage location as per your requirement requirement and click on click on

to

execute

the

transaction and you will get the report

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Status Report of Notifications Transact ion co des : IW28 / IW29 Reach the selection screen with help of following menu

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Selection screen Status check boxes

Enter Plant

Enter the selection screen values like Maint. Plants, Start & end dates, Notification no., Equipment or Function locations and select required check boxes according to the status. Click on

to execute the transaction and you will get the

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Status Report of Maintenance Orders Transact ion co des : IW38 / IW39

Trigger: To review a list of maintenance orders and make any necessary changes

Business Process Procedure Overview To generate a work list of maintenance orders to modify.

Output – Results

Comments

A list of orders.

Orders will be displayed based on the selection criteria.

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A: Logistics

 Plant

Maintenance  Maintenance

Processing

 Order  Order

List Change

B: Logistics  Plant Maintenance Processing Via Transaction Code

 History 

 Maintenance

List of Orders Change

IW38


Selection screen

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Status check boxes

Enter the selection screen values like Start & end dates, Notification no., Equipment aor Function locations and select required check boxes according to the status. Click on


following report

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Display (Multi Level) : List of Orders Transactio n c od e : IW40

Trigger: To review a list of PM orders and associated documents and master records Business Process Procedure Overview This transaction allows the planner to review a specific order along with several selected master records and documents associated with the notification.

Output – Results

Comments

A list of orders with associated documents and master records

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Logistics  Plant Maintenance  Maintenance Processing

 Order  List

of Orders 

Display (Multi-level)


IW40


Selection Screen

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Select Required Order type, Enter period dates and select different parameters for the multilevel display Now click on


following report

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Functional Location List Transaction code : IH06 Trigger: Need to look up Functional Locations. Business Process Procedure Overview You wish to search for Functional Locations by various search criteria. You may search for a location whose label is unknown, compile a list of locations that have particular characteristics in common.

Output – Results

Comments

List of Functional Locations

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Via Menus

Logistics

 Plant

 Functional


Maintenance  Technical Objects

location  List editing

 Display

IH06


Selection Screen

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Select Required Planning Plant, Maintenenace Plant, Planner Gorup etc. different parameters for the display Now click on


following report

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Equipment List Transactio n cod e : IH08

Trigger: To display a list of equipment by certain selection criteria. Business Process Procedure Overview This report is used to output a list of equipment. Equipment data comprises general data, serial number data, location data, maintenance data and sales/distribution data. You can use an equipment list to: 

Search for a piece of equipment whose number you do not know



Compile a list of equipment based on particular criteria



Perform collective processing for pieces of equipment with particular characteristics

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Output – Results

Comments

A list of equipment records

Procedural Steps Access transaction by: Via Menus

A. Logistics  Plant Maintenance System  Report Selection Technical Objects

 Information

Management

 Display

Equipment

B. Logistics  Plant Maintenance

 Planned

Maintenance  Maintenance Task Lists Environment  Engineering Technical Objects

of



 Environment 

 Equipment  List

Editing



Display


IH08


Last changed on:

Last changed by:

Version:

(23/11/2010)

RAVINDER KUMAR

1.0

Page: 239 of 241



Selection Screen

Last changed on:

Last changed by:

Version:

(23/11/2010)

RAVINDER KUMAR

1.0

Page: 240 of 241

Pm End User Manual

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