EXP_0004

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Performance-based Maintenance Planning

Business Process

Counters and MeasurementDocuments

Performance-based Maintenance Plan

Scheduling

Customer Exits

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Business Process

What must be maintainedafter how much

throughput?

50,000 l50,000 l

100,000 l100,000 l

00

001

53

Flow

Different maintenance workshould be performed on the pumps at your company based on their throughput. Hence, for example, a safety check should be performed after 50,000 litres and all the seals changed after 100,000 liters.

Preventive maintenance can be planned and performed using a performance-based strategy and regularly entered counter readings. The calculated maintenance dates are adjusted automatically based on the counter readings entered.


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At the conclusion of this unit, you will beable to:

Unit Objectives:

Create and set counters

Generate and display measurementdocuments

Create a performance-based maintenanceplan

Perform scheduling on the basis ofperformance


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Topic Overview

Business Process


Performance-based MaintenancePlan

Scheduing

Customer Exits


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015324

Characteristic:

Flow

Annualperformance:

720,000 liters

R

Creating a Counter

Counters are represented in the SAP System as a special form of measuring points. Meauring points are always created with reference to the object (for example, equipment), but are managed in their own master record in the system.

A characteristic is assigned to the counter (for example, operating hours, flow and so on). The characteristic is always used linked with the respective characteristic unit (for example, hours, liters).


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Entering an Initial Document

001500

Measuring time: 2.01.98

Characteristic: Op. hrs

Unit: Hrs.

Counter reading: 1500

Difference: 1500

Totalcounter reading: 1500


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Topic Overview

Business Process



Scheduling

Customer Exits


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Performance-based Maintenance Strategy

1997

Scheduling indicatorPerformance

Package definition

Strategy

Performance-based maintenance - Example:

Specific maintenance work should be performed on the pump after 50,000, 100,000 and 150,000 liters of throughput.

For performance-based maintenance, a strategy is defined with the scheduling indicator “Performance” (Activity).

A strategy unit is assigned (for example, liters - for preventive maintenance which is based on the volume of throughput).

In the strategy, maintenance packages are defined which use the same parameters as in time-based maintenance. For example, for the cycle length, a specific throughput quantity could be entered (for example, 50,000 liters).


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Task list

Operation 10Operation 20Operation 30Operation 40Operation 50

Operation 60Operation 70

Creating a Performance-based Strategy Plan

100,000 l100,000 l

50,000 l50,000 l

50,000 l

50,000 l50,000 l

50,000 l

100,000 l

100,000 l

50,000 l

50,000 l

Strategy

Maintenance packages define the frequency at which specific operations are executed. Maintenance packages can be assigned to the operations of a task list.

Maintenance packages are part of a maintenance strategy.

Important parameters for a maintenance package are:- Package number- Description- Cycle length- Unit of measurement- Hierarchy

If two packages are due on the same date, the hierarchy determines which package is performed.

- Offset

The offset determines the first due date for a package.

- Preliminary/follow-up buffer

The preliminary or follow-up buffer specifies the tolerance over which the intended start and end dates for a package can range.


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Topic Overview

Business Process



Scheduling

Customer Exits

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Manualcall

Manualcall

RestartRestart

Start incurrentcycle

Start incurrentcycle

ScheduleSchedule

Last actual date,Last maintenancepackage

Last actual date

Cycle start

Next planned date, Nextmaintenancepackage

Scheduling Functions

Restart: This is the function that is normally used to start a maintenance plan for an object that is just being brought into service, or for which preventive maintenance needs to be carried out.

Schedule: This is the function that is normally used to call up the next maintenance order after the last maintenance order has been completed.

Start in current cycle: You can restart scheduling for your maintenance plan in the current cycle. This function could be used in the situation where you previously managed maintenance activities without a computer system, or with a system other than SAP R/3.The maintenance strategy that you have assigned to your maintenance plan may have, for example, three packages: monthly, every 4 months and every 6 months.Instead of starting scheduling with the "monthly" package, you specify that scheduling should start with the 6-monthly package, and the date on which preventive maintenance was last carried out.

Manual call: If you also want to schedule a maintenance plan call for a particular date, you can schedule this date manually. You use a manual calls to insert additional dates without influencing normal scheduling. You enter the following data for this:- Call date - Due maintenance packages

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Calculation of Planned Dates

Calculatedplanned date

Cycle start

10.01.98

03.15.98

Annual performance36,500 liters

Cycle20,000 liters

The scheduling of a performance-based strategy plan is based on the estimated annual performance and the respective cycles. Starting from the current counter reading, a planned date is calculated from these two values.

Example:

Estimated annual performance: 36,500 litersInternal calculation of daily performance: 36,500 : 365 days = 100 liters per dayPlanned date for a cycle of 20,000 liters: 20.000 : 100 = 200 days,This means that, beginning from the cycle start, the first planned date is set after 200 days.

The planned dates can still be calculated based on, for example, the last five counter readings.

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Liters

Months

20,000

40,000

126


Estimatedannualperformance= 36,500 liters

Lineardevelopmentof throughput

Scheduling Functions (1)

A planned date is calculated on the basis of the estimated annual performancein dependency with the cycle.

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Call Horizon

Order

Cycle20,000 litersCycle start

10.01.98

03.15.98


Call horizon 90%= 18,000 liters

The call horizon is specified as a percentage and refers to the duration of the cycle. It specifies when an order should be created, with reference to a calculated maintenance date.

Example: - Annual throughput quantity: 36,500 liters- Results in a daily throughput quantity of 100 liters- Selected cycle: 20,000 liters- Results in a calculated cycle duration of 200 days- Cycle start is a counter reading of 0 liters on 03.15.98- Results in a planned date on 10.01.98- Call horizon should be 90%, meaning that the order is not created on 10.01., but on 09.11. (therefore, after 180 days).

Caution: The example above is a calculation of planned dates without taking measurement documents into consideration. If measurement documents are entered, the planned dates are recalculated on the basis of these measurement documents (see next page).

Note: If no value is specified for the call horizon when scheduling the maintenance plan, the system assumes that the call horizon is 0%. This has the result that a call is made immediately (meaning an order is created) when the maintenance plan is started, independent of the counter reading. If the duration of the cycle is to be used, it is recommended to set a call horizon of 100%.

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Liters

Months

20,000

40,000

126



Calculatedplanned dateCall

Lineardevelopmentof throughput

Scheduling Functions (2)

If you are working with a call horizon of 90%, the calculated planned date also appears in the list of scheduled calls.

The call, (creation of the order), occurs earlier:

Example:

Cycle start: 03.15.98Estimated annual performance: 36.500 litersCalculated daily perfomance:100 litersResulting planned date: 10.01.98Call horizon: 90%Call date: After 180 days, therefore, 09.10.98

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Scheduling Functions (3)Liters

Months

20,000

40,000

126


Counter readingsaccording to

measurement readingentry

Recalculatedplanned date on thebasis of measurementdocument

Call horizonreached!

Potentialcall

Call date


If a measurement document is entered, a new planned date is calculated on the basis of this measurement document, taking into consideration the estimated annual performance.

If a call horizon is also being used, the call is made earlier correspondingly (see previous page).

It a measurement document reaches the call horizon, this results in an immediate call

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Topic Overview

Business Process



Scheduling

Customer Exits

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Customer Exits

IPRM0002

In the case of strong seasonal variances (for example, in agriculture), calculation of planned dates can be structured using the customer exit IPRM0002 according to your own specifications.

The documentation for this customer exit can be called up using transaction SMOD.

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Summary (1)

Performance-based maintenance is based onthe entry of counter readings.

Every technical object which should beregularly maintained based uponperformance must have a measuring point(special form: counter) to which acharacteristic is assigned.

The planned date in the maintenance plan iscalculated based on the estimated annualperformance and the chosen strategy.

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EXP_0004

Documents

Transcript of EXP_0004