Task 1.Complete the BIA table below and use it for the remai
SAP BASED PLANT MAINTENANCE
1.
2. Definition :
Maintenance is an action required to
preserve or retain the health of equipment.
Importance:
The solution to track various day to day
activities involved in maintenance department
of any organization. Activities such as
inspection, preventive maintenance and repair
of any technical object.
3. Overview Plant Maintenance
Technical Objects & benefits
Plant Maintenance Processing & benefits
Main Reports, Standard Analysis & benefits
Overall benefits of SAP PM
4. Scope of PM Activities
Representing organizational Structures with in maintenance.
Representing and managing objects is maintained in detailed manner.
Planning and processing maintenance task in detailed manner
Inspection
Determining the actual condition of technical system
Preventive Maintenance
Maintain the ideal condition of technical system
Repair
Restore the technical system of technical object
Constructing and modifying technical system.
Processing long-term maintenance projects such as shutdown
Processing external services
Capacity planning, scheduling & resource planning
Cost planning & determination
Task based, function and object oriented plant management
Recording important data & constructing a maintenance information
system
7. Manage individual data from a maintenance perspective of the
object
Perform individual maintenance tasks for the object
Keep a record of maintenance tasks performed for the object
Collect & evaluate data for over long period of time for the
object
Time required for managing the technical object is reduced
Maintenance processing is simplified
More specific,through faster evelution of maintenance data.
Time spent entering data during maintenance processing is
reduced
8.
9.
10. A BILL OF MATERIAL ( BOM ) IS A COMPLETE
FORMALLY STRUCTURED LIST OF MATERIAL
MAKING UP A MACHINE OR ASSEMBLY
A BILL OF MATERIAL ( BOM ) IS A COMPLETE
FORMALLY STRUCTURED LIST OF MATERIAL
MAKING UP A MACHINE OR ASSEMBLY
14. Maintenance Processing
for Unplanned Tasks
PM NOTIFICATION
What
When
Where
---------------------------
Techncal
information
Breakdown
Malfunction, error
request, activity
Create the order
Planning the task
Who
When, for how long
What steps
Resources
Technical information
Breakdown
Causes
Objects affected
Activities
PM History
Execution
material issue
procuring PRTs
worksteps
Completion1
2
3
4
5
6
7
8
Requesting
a task
Releasing
the order
15. 1.Intimation of problem –
what, when, how, who,
which, why
2.Recording technical
aspects of repair – dates,
problem codes, who
repaired
3.Can be originator of
maintenance order
16. 1. Links to 1,2…n
Notifications
2. Commercial Functioning
3. Plan Labor, Spares,
External Service…..Planned
Costs & Dates…..Link with
MM, FICO, PS, HR, QM
4. Time Confirmation of
Labor, GI of Stock Material,
Service PR-PO-ES, Non
Stock Material PR-PO-GR,
Direct Bookings by
Accounts
5. Settlement
17.
18. The Plant Maintenance Information System can be
used at a variety of levels in the decision-making
process as an instrument for monitoring,
controlling and planning your business
operations.
The Plant Maintenance Information System allows
you to evaluate breakdown behavior, or the
maintenance tasks of a technical system or
machine. It is also possible to analyze the costs
incurred or the party responsible for the
maintenance tasks and the exact activities that
have been performed.
20. m
You use the selection function
for maintenance order if you
want to do following:
Change or display a
particular maint. Order,
whose no you do not know.
Change or display several
maint.
Order, which have certain
features.
Obtain an overview of
specific maint.
Order which have certain
features
Execute the same function
for certain maintenance
orders, for example release,
print, or complete
21. There are a number of standard
analyses that are defined for
reviewing data, in Plant
Maintenance (PM). These standard
analyses review the data in the
information, structures related to
manufacturers, locations, damage
analysis, breakdowns, etc.
23. The resulting data fields for the
breakdown analysis are given below:
► Order Created / Planed Orders /
Unplanned order / Completed orders
► Estimated Total Costs / Total Plan
cost / Actual cost
► Material Cost
► Service Cost
The standard analysis gives
costs for against the different
Order type, Functional Location
wise etc.
The selection criteria, allows
the maintenance user to select
following fields through which
analysis can be available. The
standard drill down is:
24. The resulting analysis produces the data
fields like:
► Notification Created / Completed
Notification
► Break down Reported
► Orders created / Completed Order /
Planned Order / Unplanned order
► Total Planed Costs / Total Actual costs
► Internal / External material costs
► Services costs
► Activities / Damage Cause
► Downtime Entered
The standard analysis for
plant maintenance for Object
class, which represent
“Object types” allows
analysis principally in
accordance with “Object
Type”.
The selection criteria, allows
the maintenance user to
select following fields apart
from the “Object Type”
through which the analysis
can be available:
25.
26. The standard analysis
for a manufacturer
allows the plant
maintenance teams to
perform a total
analysis on the data
for a manufacturer.
The selection criteria,
allows the plant
maintenance user to
select following fields.
27. Number of Notifications to the
Manufacturer
► Number of Recorded
Breakdowns that occur for objects
supplied by the relevant
manufacturer
► Number of Recorded
Maintenance Orders
► Sum of the Planned Costs for
Maintenance Orders
► Total Actual Costs of
Maintenance Services
► Total Plant Maintenance Costs
for Internal Personnel
► Total Plant Maintenance Costs
for External Contractors
► Total Plant Maintenance Costs
for Internal Materials
► Total Plant Maintenance Costs
for External Materials
► Sum of Plant Maintenance Costs
that result from Services
► Total of Miscellaneous Plant
Maintenance Costs
► Sum of the Actual Revenues for
Plant Maintenance Services
28. The standard analysis for
a plant maintenance
location allows the
maintenance staff to
review and monitor the
costs and notifications
that arise from specific or
various locations.
The selection criteria,
allows the maintenance
user to select following
fields through which
analysis can be available :
► Notification Created /
Notification Completed
► Break down reported
► Orders created / Order
Completed / Planned & Unplanned
Order / Processing Days
►Total Plan Costs / Total actual
costs / Estimated total cost
► Material Cost / Services costs
► Activities / Damage | Cause
► Downtime Entered
29.
30. The standard analysis for
a Planner group allows
the maintenance user to
analyze the data in terms
of discipline wise work
i.e. Mechanical,
Electrical, instrument etc.
The selection criteria,
allows the maintenance
user to select following
fields through which
analysis can be available:
The resulting analysis produces
data fields like : ► Notification
Created / Notification Completed
► Break down Reported
► Mean Time to Repair
► Order Created / Completed order
/ planned & Unplanned Order /
Processing days
► Total Planned Costs / Total actual
costs / Estimated Cost
► Material costs / Services costs
► Activities / Damage / Cause
► Downtime Entered
31.
32. The damage analysis
standard analysis allows
the maintenance staff to
review the data for
specific notification
types, functional
locations, or actual
equipment. This is useful
to determine The
selection criteria, allows
the maintenance user to
select following fields
through which analysis
can be available:
The resulting analysis produce data fields like
► Damage
► The number of times damage occurred and
was entered in a notification
for describing the recorded damage
► Causes of Damage
The number of cause of damage codes
recorded for a technical object to
explain the recorded cause of damage in the
notification
► Activities
The number of activity codes recorded to
describe the executed activities
in the notification.
33.
34.
35. The breakdown standard
analysis is similar to the
damage analysis, but this
analysis refers specifically
to the breakdown of
equipment and the costs
involved in maintenance.
This analysis is useful for
maintenance staff working
on equipment warranty and
replacement.
The selection criteria,
allows the maintenance
user give analysis through
selection of following
fields. The standard
drilldown is:
The resulting data fields for the
breakdown analysis are given below:
► Actual Breakdowns
► The number of breakdowns that
actually occurred with a technical
object.
► Mean Time to Repair
The mean of the sum of the actual
periods of time for correcting a
technical object malfunction, or the
actual times it took to repair the
object.
► Mean Time between Repairs
The mean of the sum of the times
between the termination of a machine
36.
37. · Preventative Maintenance
The SAP PM module is able to plan and manage scheduled, proactive, maintenance
procedures designed to prevent, or predict, breakdowns to critical systems, which can be
costly not only in terms of repair, but also in terms of lost production. In difficult,
demanding industries, such as the oil production industry, the SAP PM module can increase
the availability of the multitude of pumps, valves and other equipment that constitute an oil
drilling platform.
Problem Rectification
The SAP PM module also allows maintenance organizations to identify and rectify problems
with any of the equipment under their control, whether they’re cause by complete failure or
deterioration over time. The SAP PM module automatically pinpoints the exact location of
faulty equipment and generates a detailed maintenance order, including any necessary
specifications, engineering drawings and safety precautions. All of these details are critically
important because if any of them are missing maintenance may not be possible, potentially
halting production or endangering lives or both.
Split-level Maintenance
One of the major benefits of the SAP PM module is that it allows plant maintenance to be
broken down into various levels, at both the planning and performance stages. The SAP PM
module obviously permits individual, independent equipment, such as vehicles, to be
maintained independently, but also permits other types of equipment, such as a production
line -- which consist of several pieces of interdependent equipment -- to be maintained as
a “functional location,” rather than a collection of independent components.
Other Benefits
Overall, the SAP PM module allows plant maintenance businesses and functions to be
standardized across an organization and integrated with other functions. In so doing, it
reduces reliance on paper-based systems or standalone computer systems. Furthermore,
the SAP module creates structured information -- with regard to the cost and technical
history of critical systems -- which affords better control of resources, manpower and
overall maintenance costs. The SAP PM module also serves to promote the ownership of
maintenance data among its users, as well as the monitoring and improvement of
performance measures as far as plant maintenance is
