Contents Abstract ......................................................................................................................................................... 2 Purpose ................................................................................................................................................. 2 Overview of refurbishment process ............................................................................................................. 2 Repairable spares .......................................................................................................................................... 3 Split valuation ............................................................................................................................................... 3 Prerequisites: Configuration for refurbishment order type ......................................................................... 4 CONFIGURE REFURBISHMENT ORDER TYPE: ................................................................................................ 4 INDICATE ORDER TYPE FOR REFURBISHMENT PROCESSING: ....................................................................... 6 Maintaining the number range ..................................................................................................................... 6 Assign order types to maintenance plants ................................................................................................... 6 Assign costing parameters to order .............................................................................................................. 7 Goods movement for orders ........................................................................................................................ 7 The process of Refurbishment order ............................................................................................................ 8 Define split valuation type ........................................................................................................................ 8 Return defective spare parts to warehouse ............................................................................................. 8 Create refurbishment order...................................................................................................................... 8 Release and execute order ....................................................................................................................... 8 Withdrawal of repairable spares to be refurbished from the warehouse ............................................... 8 Return of refurbished repairable spares to the warehouse ..................................................................... 8 Order technical completion ...................................................................................................................... 8 Order settlement ...................................................................................................................................... 8 Order business completion ....................................................................................................................... 8 References .................................................................................................................................................... 8
Abstract Purpose This document describes how the refurbishment process for repairable spares configured in Plant maintenance
The refurbishment of repairable spares is important for companies, for which system availability is a critical factor (for example, the process industry, oil producing and processing, steel processing) and for which repairable spares guarantee a high level of system availability. The refurbishment of - usually high value - faulty repairable spares is of considerable economic importance for these companies and is often a core process in Plant Maintenance. It is often much more cost-effective than a brand new purchase. •
Setting of refurbishment process related functions
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The key process of refurbishment process
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The effect of refurbishment process in R/3
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Visio- process flow
Overview of refurbishment process High value components are often used at production plants or other technical objects (for example, pumps, motors) and are replaced by a repairable spare in the event of a malfunction and then refurbished using a separate order. This scenario is of particular interest to companies for which system availability plays a crucial role (for example, process industry, oil extraction and processing, steel manufacturing and so on), and who keep repairable spares in stock to ensure a high system availability. The refurbishment of these defective spares, which are generally of high value, is of great economic importance for these companies and is often a core process within their maintenance department. The refurbishment of repairable spares is important for companies, for which system availability is a critical factor (for example, the process industry, oil producing and processing, steel processing) and for which repairable spares guarantee a high level of system availability.The refurbishment of - usually high value - faulty repairable spares is of considerable economic importance and is often a core process in Plant Maintenance. It is often much more cost-effective than a brand new purchase. In production plants or other technical objects, high value components are often used (pumps, motors and so on) which are replaced in case of damage by a functional repairable spare and then refurbished using a separate order.
Repairable spares An inventory-managed single unit of material which can be uniquely identified by a combination of material and serial numbers, with an additional equipment master record if necessary.
Repairable spares can be refurbished many times for defects or wear, and then made available again as spare parts. Repairable spares are reserves in the warehouse for certain critical and high-value components, so that these parts can be replaced immediately in the case of a breakdown. These are managed in the form of material master record.
Split valuation Split valuation enables you to valuate substocks of a material in different ways (for example, according to external procurement or in-house production or by batches). Repairable materials are valuated based on their status.
Example: The material XYZ has following valuation types. New(C1) Defective(C2) Refurbished(C3)
b) CONFIGURE SPLIT VALUATION:
Menu path:
SPRO>Material management>Valuation & Account assignment>Split valuation>Configure split valuation.
In this step, you configure whether split valuation is allowed at your company.
If you generally allow split valuation, this does not mean that you must valuate each material on this basis. You decide whether to do so or not for a particular
material when creating the material master record. In the standard SAP R/3 System, split valuation is set so that it is active.
Click the “ Configure split valuation”
In split valuation, you can distinguish between partial stocks of a material according to certain criteria and valuate them separately.
The material stock is divided according to valuation category and valuation type:
o The valuation category determines how the partial stocks are divided, that is, according to which criteria.
o
The valuation type describes the characteristics of the individual stocks
Prerequisites: Configuration for refurbishment order type CONFIGURE REFURBISHMENT ORDER TYPE: Menu path:
SPRO>Plant maintenance>Maintenance processing>Maintenance orders>Functions & settings for order types>Configure order type.
Transaction code: OIOA
In this step, you set up your order types for Plant Maintenance and Customer Service.In addition to the business reasons for configuring several order types,there are also technical controls which depend on the order type and may require the creation of different order types.
Selelect the order type PM04
The following technical controls depend on the order type:
o
Number ranges
o
Settlement proposal or account assignment rule
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Default values for controlkey
o
Permitted maintenanceactivity types and default values
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Permitted order types for each maintenance planning plant
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Increment when assigning the operation numbers
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Costing parameters
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Residence period of the order after completion (residence time)
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Default values for the confirmation process
o
Presetting for the referenceobject screen
We have to maintain settlement profile for materials.
INDICATE ORDER TYPE FOR REFURBISHMENT PROCESSING: Menu path:
SPRO>Plant maintenance>Maintenance processing>Maintenance orders>Functions & settings for order types>Indicate order type for refurbishment processing.
Transaction code: SPRO
In this Customizing activity, you can allow the individual order types refurbishment processing.
This business process usually involves a special form of Plant Maintenance which is treated differently from maintenance, repair and inspection orders in terms of planning, time and costs. In order to maintain refurbishment order tick the check box in the following screen shot.
Maintaining the number range Menu path:
SPRO>Plant maintenance>Maintenance processing>Maintenance orders>Functions & settings for order types>Maintain number range
Transaction code: OION
In this step, you define the number ranges for the individual order types.
From the point of view of program control and selections, it is not necessary to define different number ranges for the individual order types. If your company does not need to define several number ranges, you can work with one number range for the maintenance or service orders.
Assign order types to maintenance plants Menu path:
SPRO>Plant maintenance>Maintenance processing>Maintenance orders>Functions & settings for order types>Assign order types to maint.plants
Transaction code: OIOD
In this Customizing activity, you determine the order types allowed for the individual planning plants. If you want to allow all order types for all planning plants, you must enter all the order types for each plant.
Assign costing parameters to order Menu path:
SPRO>Plant maintenance>Maintenance processing>Maintenance orders>Functions & settings for order types>Costing data>Assign costing data parameters
Transaction code: OIOF
In this step, you can set the costing parameters for maintenance and service orders. You can also assign a resultsanalysis key to each order type. Before you set the costing variants for orders, you must create the costing variants. resultsanalysis key defines the valuation of the order during period-end closing.
Goods movement for orders Menu path:
SPRO>Plant maintenance>Maintenance processing>Maintenance orders>Functions & settings for order types>Goods movements>Define documentation.
Transaction code: SPRO
In this Customizing activity you can define which types of goods movement are documented for each individual PM order. This function can be called from order processing in list form.You can determine whether the list contains.
1.Goods receipts in respect of purchase orders for the order A goods receipt for the purchase order is documented for both evaluated and non-evaluated goods receipts.
2.Planned goods issues for the order(Reservation).
3.Unplanned goods issues for the order.
4.Goods receipts for the refurbishment order in the case of a refurbishment order.
The process of Refurbishment order Define split valuation type Return defective spare parts to warehouse Create refurbishment order Release and execute order Withdrawal of repairable spares to be refurbished from the warehouse Return of refurbished repairable spares to the warehouse Order technical completion Order settlement Order business completion
References http://help.sap.com
