1. SAP Plant MaintenancePresentation By:Mr. Subhrajyoti BhattacharjeeB.E., P.G.D.M., PMP, Certified SAP PM Solution Consultant

2. Brief Background of Presenter Subhra works as SAP Systems Analyst at Iluka Resources Limited, Perth, Western Australia He has a Net experience of around 7.8 years with around 6 years of SAP Consulting Experience in SAP PM & CS, MM modules. He has also has standard configuration knowledge of SAP PS, DMS and integration aspects of other SAP modules & applications Hehas workedinmultiple SAP Implementation, Upgrade, Support & Audit assignments in Australia, USA, India and Middle East and is an ex- employee of PwC India Ltd, T.C.S. Limited He also possesses Core Industry experience of 1.8 years in Maintenance & Inbound Logistics 3. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosAdvanced scenarios, Interfaces & Reports 4. Government& AuthoritiesVendors OrganizationCustomersEnvironment 5. ExternalVendors EnvironmentOrganizational ERP System Finance &Controlling PurchasinProjects gProductionPlanningHR &PayrollSales & Distributio Maintena n nceGovernment & Customers Authorities 6. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosAdvanced scenarios, Interfaces & Reports 7. Maintenance is a Support Function within an Organization and Maintenancecosts generally constitute a part of Production overhead costs except whenMaintenance is carried out on Customer Assets to earn revenue. Primary Objective of Maintenance is to maintain a high level ofAvailability, preventing degeneration and maintaining optimal utilization life of anOrganizations Physical Assets. Physical Assets primarily comprise: Fixed assets such as Plant & Machinery, Buildings & Properties, Vehicles andso on. Usually such assets have a Long useful life (usually > 1 year) over whichthey are depreciated Operating Assets which may not be treated as Assets in Financial Module nordepreciated, but having a long term utilization High valued current assets such as High valued spares/operatingsupplies/machine parts which are subject to Refurbishments with their conditionbased values maintained accurately Key Performance objectives in Maintenance include Maintaining a high level of OEE (Overall Equipment Effectiveness)Maintaining and Optimal balance between Cost of Breakdown vs. Cost ofPreventionUtilizing concepts such as TPM, RCM etc. to contribute in Lowering Operatingcosts and minimize adverse effects on Equipment ,Operating resources and 8. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosAdvanced scenarios, Interfaces & Reports 9. CompanyCentralized CodeDe-centralizedPlanningPlanningMaintenanceMaintenance Planning Planning PlantPlantMaintenance MaintenanceMaintenance Plant PlantPlant 10. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosAdvanced scenarios, Interfaces & Reports 11. Technical Objects SAP WorkPM:PlanningCentres MasterObjects Data Others 12. Work Centre Work Centre Hierarchy is aHierarchGrouping of Work centres ycomprising Maintenance TaskForceWorkCapacityCentre Capacity information includes: PM Work Centre Category 0005 Comprises: Basic data, Default values, Capacity Unit of capacityview, Scheduling Start/End times view, HR Assignments, Costing Utilizationsview Shift schedules etc. 13. LoadMonitoringCapacityPlanning Capacity LevelingCapacity Functionalities 14. Functional Locations Structured into Hierarchical Levels using Structure Indicators Equipment Serial Number Sub EquipmentMaterial NoEquipment Bill of MaterialComponent material parts 15. PlanTop DownBottom upplanningplanning Task List Maintenance item 16. Single cycle Plans Strategy Based PlansPlans Counter Based Plans (Single/Multi Counter) General Task Lists Functional Location Task ListsTask Lists Equipment Task Lists Standard items Strategy based itemsItems 17. Other MasterData Measuring Points/Counters Class/ Characteristi cs Permits 18. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosAdvanced scenarios, Interfaces & Reports 19. Maintenance Notifications vs. MaintenanceOrders Maintenance Maintenance OrdersNotifications are are a complete recordReporting objects toof:record: Operations performed Maintenance requirement Components used Cause, Object (Stock/Non stock)Impacted, Tasks due & Services hiredActivities Performed Time and costs posted Types: Maintenance Settlements executedRequest, Malfunction(Breakdown) Types: BreakdownReport, ActivityOrders, PlannedReport, Service Orders, PredictiveNotifications Orders, CalibrationsOrders, Refurbishment Maintenance NotificationsOrders, Capital Work 20. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosAdvanced scenarios, Interfaces & Reports 21. Master DataFunctional MaterialWork centerEquipment Location(Stock parts) (PM & PP)Production personnel Permits (If ActivityServicefollows up on work done against existing applicable)Type Master record NotificationYesFurther work done isrecorded in SAP Notification mail toExisting Notification Notification&initiator of work(Report IW29)? Notification Tasks Technically completedNoNoSAP Notification mail toNotification user PM OredrMaintenance designated Personstatus changed toPlanning done Equipment breaks Convert to PMOrder (TypeNotification (Typeresponsible in Yes ALWD and(Operation,down Order? PM01) created M2) createdNotification headernotification Components,released Service, Permits)Shop papersprinted from PM orderGoods receipt to StorageIssue stock part to Reservation No location assigned to PM OrderStock part YesApproved purchase Purchaserequisitions converted to requisition created Order user statusAssigned permits if Is stock part Is Stock partPurchase order(MM side) No Yes changed to PLNDany are issued byavailable? planned? and order releasedrelevant personnelNoApprovedpurchase PurchaseGoods receipt against POrequisition requisitions Is Non stockposts costs to associatedconverted to created within Yespart planned?PM orderPurchase order PM order YOrder settled to relevant No Yessettlement receiver (CostCenter) Approved Service acceptancePurchase purchasethroughService entryrequisitionIs ExtenalIs further planningrequisitionssheet against Service POcreated within servicerequired?converted toposts costs to associatedPM orderplanned? Purchase orderPM order No ProductionSettlement rule defined inUser status ofpersonnel toTime confirmationorder & Order Technically Maintenance order confirm Orderfor Manhours with Is Maintenancecompleted with details ofchanged to MTCO Yes No completion by suitable Activity work completed?Malfunction end date/time Completed by changing userTypestatus to PRCOMaintenanceIn SAPOutside SAP 22. Master DataFunctionalMaterialWork center ServiceEquipment Location (Stock parts) (PM & PP) Master record Counter (ForPermits (IfActivityMaintenance Maintenancecounter basedapplicable) TypeTask List Plan plans)Measurement Planned Due document postingdates for order for Counter Based creation are set in plans systemOrders generated Maintenance Plan Scheduling overview for the periodare Maintenance planIs next call object Preventivecreated (Single report generated byplanned furtherMaintenance Taskcycle/StrategyscheduledMaintenance OrderYes Maintenance ordermaintenance List created(Background job/due?(TypePM02")(Operation,based/Counter personnel on aComponents, Manual)generatedbased) periodic basis Service, Permits) Shop papers printed fromPM orderGoods receipt to StorageIssue stock part to Reservation No location assigned to PM Order Stock partYesApproved purchase Purchaserequisitions converted to requisition createdOrder user statusAssigned permits if Is stock partIs Stock partPurchase order(MM side) No Yeschanged to PLNDany are issued byavailable?planned?and order releasedrelevant personnelNoApprovedPurchasepurchase Goods receipt against POrequisition requisitionsIs Non stock posts costs to associated created withinYes converted topart planned? PM order PM orderPurchase orderYOrder settled to relevant NoYessettlement receiver (CostCenter)Approved Service acceptancepurchase PurchasethroughService entryrequisitions requisitionIs ExtenalIs further planningsheet against Service POconverted to created within servicerequired?posts costs to associatedPurchase order PM orderplanned?PM order No ProductionSettlement rule defined inUser status ofpersonnel toTime confirmationorder & Order Technically Maintenance order confirm Orderfor Manhours withIs Maintenancecompleted with details ofchanged to MTCO YesNo completion by suitable Activitywork completed? Start/end date/timeCompleted by changing userTypestatus to PRCOMaintenance In SAP Outside SAP 23. Master Data FunctionalMaterialWork center Service EquipmentLocation (Stock parts) (PM & PP) Master recordCounter (For Permits (IfActivityMaintenance Maintenance counter based applicable) TypeTask List Planplans) Measurement Planned Duedocument postingdates for orderfor Counter Based creation are set inplans systemMaintenance TaskMaintenance Plan Scheduling overviewCalibration Orders autoMaintenance planIs next call object Preventive List createdcreated (Single report generated bygenerated and released(Inspection pointcycle/Strategy scheduledMaintenance OrderYes Maintenance ordermaintenance (Operation,(Background job/due?(TypePM02") 300, MICsbased/Counter personnel on aComponents, Service,Manual)generated entered)based) periodic basisPermits) Goods receipt to StorageIssue stock part to Reservation Nolocation assigned to PM OrderStock partYesShop papersprinted from PM order Approved purchase Purchase requisitions converted to requisition created Quality Inspection LotIs stock partIs Stock part Purchase order(MM side) No Yes Generated available?planned? Order settled to relevant Nosettlement receiver (Quality Cost Center)Approved Purchase purchaseGoods receipt against POrequisitionrequisitionsIs Non stockposts costs to associated created withinYesconverted topart planned?PM order PM order Purchase order Y NoYes Result recording doneApprovedagainst Inspection Lot, Order Service acceptancepurchase Purchase Technically completed throughService entryrequisitions requisitionIs ExtenalIs further planning sheet against Service POconverted to created within servicerequired? posts costs to associatedPurchase order PM orderplanned? PM orderNo Time confirmationfor Internal Settlement rule set in Is MaintenanceManhours withYesNo Calibration order work completed?suitable Activity Type In SAP Outside SAP 24. Master DataFunctional MaterialWork centerEquipment Location(Stock parts) (PM & PP) Permits (IfActivity Service Requestor checks on workprogress applicable) TypeMaster recordYesWork detailed inSAP Notification mail toNotification and TasksExisting Notificationinitiator of workTechnically completed(Report IW29)?No NoNotification userPM Oredr Scope for correction/ MaintenanceSAP Notification mail to status changed to Planning donepredictive maintenanceNotification (Typedesignated PersonConvert to PMOrder (Type Yes ALWD and (Operation,identified by Operator/ M1 Maintenanceresponsible inOrder? PM01) created notificationComponents, Maintenance personrequest) created Notification headerreleasedService, Permits) Shop papers printed fromPM orderGoods receipt to Storage Issue stock part to Reservation No locationassigned to PM OrderStock part YesApproved purchase Purchaserequisitions converted to requisition created Order user status Assigned permits if Is stock part Is Stock partPurchase order(MM side)NoYes changed to PLND any are issued byavailable? planned? and order released relevant personnel NoApprovedPurchasepurchaseGoods receipt against PO requisition requisitions Is Non stockposts costs to associatedcreated withinYes converted to part planned?PM orderPM orderPurchase order YOrder settled to relevantNoYessettlement receiver (CostCenter) Approved Service acceptancepurchase PurchasethroughService entryrequisitions requisition Is ExtenalIs further planningsheet against Service POconverted to created withinservicerequired?posts costs to associatedPurchase order PM order planned?PM orderNo ProductionSettlement rule defined in User status ofpersonnel toTime confirmationorder & Order TechnicallyMaintenance order confirm Orderfor Manhours with Is Maintenancecompleted with details of changed to MTCO Yes No completion by suitable Activity work completed? Start/ end date/timeCompleted by changing userTypestatus to PRCO MaintenanceIn SAP Outside SAP 25. Master Data Asset Master Functional Material Work centerAuC/FxA (AsLocation(Stock parts)(PM & PP) relevant)Permits (IfActivity Service Equipmentapplicable) TypeMaster record (Associated toFxA)Asset under Maintenance Team Functional Location (for asset construction createdintimated on the AuCbuild up created) as reference New Asset buildupby Business SAP NumberTechnical object Finance TeamCapital work New asset build up or EnhancementOrder PlanningCapital work Order (Type done (Operation, Existing Equipment No (with PM06) created withComponents,Asset Enhancementassigned Fixed asset) wouldrelevant Maintenance Service, Permits), be identifiedActivity type assignedSettlement ruledefinedShop papersprinted from PM order Goods receipt to StorageIssue stock part to Reservation Nolocation assigned to PM OrderYesStock partFunctional Location StructureApproved purchase Purchase requisitions converted to requisition createdIs stock partAssigned permits ifcompleted with assigned NoIs Stock part Capital order Purchase order(MM side) available? Yes any are issued by Equipment tagged to FxAplanned? released relevant personnel numberNo Approved Purchase purchase Maintenance Team Goods receipt against POrequisitionintimated on the FxArequisitions Is Non stockposts costs to associated created withinYesconverted to part planned? Number PM order PM order Purchase orderYNo Yes ApprovedService acceptance PurchaseIn case of Asset buildup work, purchase throughService entry requisition Is Extenal Is further planning Finance finally settles AuC to requisitions sheet against Service PO created withinYes service required? a FxA ( created) converted to posts costs to associated PM order planned? Purchase order PM order NoTime confirmationOn completion of work Order Periodic settlementfor Manhours withIs Maintenance Technically completed with executed to relevant YesNo suitable Activitywork completed? necessary detailsreceiver (AuC/FxA)Type In SAPOutside SAP 26. Master DataRef. Material (with PM Work center valuation types Serial Equipment (For InternalC1, C2, C3) NumberRefurbishment)Batch Numbers for C1,Asset NoService Activity C2, C3 states of Ref (Tagged to material Master recordType Equipment ID)Refurbishment order typeOrder Planning done PM04" created for Material(Operation Internal orNeed for Refurbishment No, to convert from C3 - External Services, Additional identifiedDamaged to C2 - Components if any), Refurbished stateSettlement rule defined Shop papers printed fromPM order Goods receipt to Storage Issue stock part to Reservation Nolocationassigned to PM OrderStock part Yes Approved purchasePurchase Additional requisitions converted torequisition createdDamaged Material part Available inStock partsOrder released Purchase order (MM side)NoYes(valuation type C3) issued to stock? required/ reservation no. in orderplanned?NoApproved PurchasepurchaseGoods receipt against POrequisition requisitions Is Non stockposts costs to associated created withinYes converted to part planned?PM order PM orderPurchase orderYNoYes ApprovedService acceptance PurchaseSettlement executed to settlepurchase Is Extenal throughService entry requisition Is further planningorder costs (As per businessrequisitionsRefurbishment sheet against Service PO created within required? requirement to FxA)converted toservice posts costs to associated PM order Purchase order planned? PM orderNoTime confirmationfor Manhours withOn completion of work OrderGoods receipt ofsuitable Activity Is Maintenance Technically completed with Refurbished part (val. TypeYes NoType In case ofwork completed? necessary detailsC2") to store internal manhour consumedIn SAP Outside SAP 27. ERP Systems: An OverviewPlant Maintenance: An Overview Organizational Structure Master Data in SAP PM Maintenance Processing: ObjectsMaintenance Processing: ScenariosIntegrations, Advanced scenarios, Interfaces & Reports 28. Plant MaintenanceControllingQM MasterEmployeEquipmentse Sender CostActivity FunctionalPlanned NotificationPM Work Center TypesLocation Rates /hr FinancialCenterAccountingReceiver Cost Center MaintenanceOrderG/LFixed EquipmentPlan HeaderAccountAsset Material Management Operation- InternalShutdown Operation Services Service MasterPP WorkBOM SparesComponeCenter -ntMachine Material Master Costs 29. PM - Customer Service Scenarios PM - Work Clearance Management PM Fleet Management PM Mobile Asset Management ** PM Project Oriented Maintenance** PM Linear Asset Management ** PM Rotables Subcontracting ** PM Inspection Rounds ** PM Take over- Hand over of Equipments** Functionalities available only in ECC 6.0 and in specific EHP versions 30. SCADASAP BW SAP Plant Maintenance OthersSAP MI 31. Maintenance Cost Analysis Report Wave- I Wave- II 32. Man hour Utilization ReportWave- IWave- II 33. Downtime Analysis Report Wave- I Wave- II 34. MTTR/MTBF Report Wave- I Wave- II 35. Cause and Effect Analysis Report Wave- I Wave- II 36. Preventive Schedule Overview ReportWave- IWave- II 37. Material Goods Movement/Consumption Report Wave- I Wave- II 38. Thank you !!