Solution Overview Of

Plant Maintenance & other Module

Integration
In
SAP S/4HANA 1809 and Fiori

Enabling @Chromeni Steel through SAP Solutions

Agenda
Overview of SAP Plant Maintenance
• SAP Plant Maintenance module is a comprehensive solution that
provides tools for maintenance activities within a company.
• The SAP PM module consists of activities such as: management of
technical objects, maintenance processing, and preventive
maintenance.
• It is used to comprehensively plan, schedule, and execute the daily
maintenance activities with integration to other SAP modules
• Maintenance processing helps to control the actual maintenance
work conducted in the maintenance plant.
SAP Plant Maintenance
• The SAP PM module is designed to cover maintenance activities and the
control of both machinery and facilities. SAP PM helps to integrate and
optimize the scheduling and planning of inspection, preventive
maintenance, and repair activities.
 Successful implementation of the PM module brings benefits in various
ways such as :-
• All maintenance work is managed in one system,
• Better communication within the organization,
• Full usage of Bills of Material (BoM),
• Clear set up for maintenance plans, reporting, and better usage of
Production capacity.
Organization Structure
Master Data
Basic Function of Maintenance Processes
• Depending on the field of business, size of the enterprise, number of
plants, requirements for the maintenance, and management decision, the
PM structure can be described in the system in various ways. Basic
components to be used in all cases are maintenance planning plant,
maintenance plant, and technical object ( Functional Location , Equipment ,
Work Center etc ).
• SAP PM functions basically divided into four activities:-
- Inspection: all measures that indicate the condition of a technical object
- Preventive maintenance: all measures that help to keep technical system in
optimal condition
- Repair: all measures that recondition a technical system
- Other maintenance activities
Maintenance Process Flow
Breakdown Maintenance Process
Flow Chart Of Breakdown Maintenance Process
PROCESS FOR HANDLING BREAKDOWN WITH MATERIAL/EXTERNAL SERVICES REQUIREMENT

Breakdown Occurs

Production/Maintenance Department
raises Notification mentioning Problem
description, Equipment number and Communication
Malfunction start time occurs

Maintenance Engineer
inspects Equipment and
Plans for the job

Create No
Matl Get reservation
Maintenance
number and
Order and Carry out
Is material or External issue material
allocate the job Is the Problem
Service required to carry from stores
components (Outside rectified ?
out the job? against
and release SAP)
reservation/
order
order
Issue Permits
Service Yes

Create Maintenance Order

Creates
reservation/ FI Document Generation
Allocate External services to Purchase Material Doc. Generation Close Notification
Order, mention quantity, price Requisition CO Document Generation
and cost element

Release maintenance Order

Technically Complete
Create Purchase order with PO Number Maintenance Order
reference to Requisition generated

Carry out job with the help of

external agency
Settle the order
No
Is the problem solved ?

Business Completion of
Yes
FI Document Generation order (By PP department)
Material Doc. Generation
Create Service Entry sheet
CO Document Generation
and accept

Complete Notification with all

details and Technically
Complete the order
Settlement
Communication Document
Order Settlement
occurs Generated

Business Completion of
Order ( By PP department)
MTBR – Mean Time Between Repair
• The average amount of operating time between consecutive breakdowns for an item of equipment
(or plant).
• Formula MTBR =
Operating Time
Number of Failures or Breakdown Events

– Operating time is productive time plus production delays.

– Number of failures or breakdown events is the number of failures on an item of equipment (or plant).

• Maintenance effort required is decreasing.

• Maintenance practices / mechanisms are effective.
• Failure frequency is decreasing.
• Operating conditions are improving.

MTBF
• Interpretation
• Maintenance effort required is increasing.
• Maintenance practices / mechanisms are ineffective.
• Failure frequency is increasing.
• Operating conditions are deteriorating.
MTTR – Mean Time To Repair
• The average maintenance time required to keep an item of equipment (or plant) operational.
• Formula M TTR =
D o w n T im e
N u m b er o f F ailu res o r B reak d o w n E v en ts

– Down time is the total time equipment (or plant) is down for maintenance work (preventive and corrective).
– Number of failures or breakdown events is the number of failures on an item of equipment (or plant).

• Maintenance practices / mechanisms are ineffective.

• Poor clean-up (work preparation) practices.
• Ineffective work practices.

• Interpretation MTTR

• Maintenance practices / mechanisms are effective.

• Clean-up (work preparation) practices effective.
• Effective work practices.
Corrective Maintenance Process
Flow Chart of Corrective Maintenance Process
PROCESS FOR HANDLING ROUTINE MAINTENANCE ACTIVITIES

Communication
occurs
Production/Maintenance Department raises Notification
mentioning Routine maintenance to be carried out

No No

Is material or External Carry out

Is the job done
Service required to carry Maintenance Job (
out the job? satisfactorily?
Outside SAP)

Yes
Yes

Create Maintenance
Order
Communication Creates Close the notification after
occurs Allocate components /External reservation/
putting all details
Purchase
services to Order, Issue Permit,
requisition
Release order

Issue Components/ Create Generates

Purchase Order material doc
Generates FI doc Communication
Generates CO occurs
Carry out doc.
Maintenance Job (
Outside SAP)
No

Is the problem solved ?

Yes Generates
material doc
Generates FI doc
Create Service Entry sheet Generates CO
and accept doc.

Communication Complete Notification with

Generates
occurs all details and Technically Settlement
Complete the order document

Settle the order

Business Completion of
Order
MTBR and MTTR Report
Preventive Maintenance Process
• Preventive Maintenance in an organization is used to avoid system breakdown and
production breakdown . Preventive maintenance term is used to perform inspections
and repairs. Maintenance plans are used to define dates and the extent of
preventive and inspection maintenance tasks which can be planned for technical
objects.
 Following are the key benefits of using Preventive Maintenance in an organization:-
• The activities that are performed in Preventive Maintenance are stored in the form
of task lists.
• You define the extent and inspection work, and when the preventive maintenance
should be performed with details of the functional location or pieces of equipment.
• You also define the cost-based assignment of Preventive maintenance task lists.
• You can also perform a review to find the cost of preventive maintenance activities
to be performed in future.
Flow Chart of Preventive Maintenance Process
PROCESS FOR HANDLING PREVENTIVE MAINTENANCE

Create Maintenance Strategies ( Time-based/

Performance based) and define packages

Create tasklists - Equipment / general and

allocate maintenance package

Create Maintenance Plan for each equipment(Six-

yearly/annual/monthly/weekly)

Schedule Maintenance Plan (Weekly, Monthly, 6

monthly, Annual, 4-6 years)

View Preventive Maintenance Orders

Carry out Preventive Maintenance jobs

Generates
Reservation/
Allocate Components/Services, if necessary Purchase
Issue Permits Requisition

PO Number
Convert Purchase requisition to PO in case of generated
external service requirement

Generates
Issue component against order/reservation material document
Generates FI doc
Generates CO
doc.

Note down observations/ activities performed

against each operation
Generates
material document
Generates FI doc
Create Service Entry sheet for external services Generates CO
doc.

Close the Notification/Technically complete the

Communication
order
occurs

Settlement
Document
Settle the order Created

Business Completion of order ( By PP

department)
Refurbishment Maintenance Process
• Refurbishment is defined as the process of repairing spare parts and
returning the spare parts to the warehouse or to the equipment. You can
define a Refurbishment order as Maintenance order by which we can
execute the process of refurbishing damaged equipment. To perform this,
we need a material and serial combination.
• As a part of the Refurbishment process, you can uninstall the damaged
equipment or material from the maintenance plant and it is moved to the
Storage Location . A Refurbishment order is created to collect the cost for
the refurbishment process.
• Once the Refurbishment process is completed, you change the conditional
state of material from damaged to Refurbished state. The Refurbished
equipment can be reinstalled in the maintenance plant and the order is
closed.
Flow Chart of Refurbishment Maintenance Process
PROCESS FOR REFURBISHMENT ORDER

Create Spare Parts with Spilt Valuation Type

Assign Valuation Type to Created Material

GRN created. FI
Upload Material in Central Store document
generated

Material doc.
Issue Material with respect to Maintenance Order Generated
(with Batch Type C1) FI doc. Generated
CO doc.
generated

During failure of part, transfer Defective Material

to Maintenance Store (with Batch Type C2)
Communication
occurs

Create Refurbishment Order (Valuation type to

be Changed From C2 to C3)
Generates
Reservation/
Purchase
Allocate Components/External Service to order Requisition

Release the refurbishment order

Generates
material doc
Issue components against reservation/order Generates FI doc
Generates CO doc

Create Purchase requisition to PO for external

service

Receive Repaired Material to Maintenance Store

after Repair Work

Generates
material doc
Create Service entry sheet and accept Generates FI doc
Generates CO doc

Technically complete the order

Generates
Settle The Refurbishment Order Against Material Settlement
document

Business Completion of order ( By PP

department)
Standard Reports of SAP PM
Material Where Used List Report
Location Analysis
Breakdown Analysis
Cost Analysis
1. Employee – Maintenance Info
2. Maintenance Technician
Report and Repair Malfunction
Maintenance Notification
Technical Object Damage
Maintenance Order Confirmation
Mass Schedule of Maintenance Plan
THANKS