SAP Plant Maintenance Module Overview

2
Agenda
Introductions
PM Module Structure
Customer Service Module
SAP Integration
PM Module Implementation
Questions, Discussion, Follow Up Actions
Appendix ! SAP Screen Captures "ver #$%&'
3
Plant Maintenance Module Structure
4
R/3
R/3
Client / Server Client / Server
ABAP/4 ABAP/4
FI FI
Financial Financial
Accounting Accounting
CO CO
Controlling Controlling
AM AM
Fixed Assets Fixed Assets
Mgmt. Mgmt.
PS PS
Proect Proect
S!stem S!stem
"F "F
"or#$lo% "or#$lo%
IS IS
Industr! Industr!
Solutions Solutions
MM MM
Materials Materials
Mgmt. Mgmt.
&R &R
&uman &uman
Resources Resources
S' S'
Sales ( Sales (
'istri)ution 'istri)ution
PP PP
Production Production
Planning Planning
*M *M
*ualit! *ualit!
Mgmt. Mgmt.
PM PM
Plant Plant
Maintenance Maintenance
SAP Database Integration
5
SAP Data Structure
Con(iguration
Implement Design Decisions
)er* +imited Access
,est Across all Modules
Ca$ -.. PM con(iguration nodes
Master Data
/0uipment 1 Functional +ocations
Materials
)endors
Personnel
+imited Access
,ransactional Data
/ntered &* personnel doing t2e wor3
Single /ntr*
6
Key Benefits of SAP Plant Maintenance Module

4ecords 5istor* to +ocation and /0uipment

Captures all Costs (or a 6or3 Order

Direct +in3 to Store room "M4O'

Direct +in3 to Purc2asing

A&ilit* to C2ec3 (or /0uipment Spares

A&ilit* to )iew 6or3 +oad Capacities

Allows (or Maintenance 4eporting

Allows (or Comparison o( Planned and Actual Costs

+in3s /0uipment to Plant +ocations

,rac3s and Sc2edules Preventive Maintenance

Allows Sc2eduling o( S2utdowns 1 ,urnarounds

7
Master Data
/0uipment
Master
Functional +ocation
,as3 +ist
7ill o( Materials
6or3center
Classi(ication
SAP PM Organi8ational /lements
6or3 Order
Management
9oti(ication
6or3
Order
Planning
Sc2eduling
: /xecution
4eport
+a&or
Material
Ac0uisition
4eport
5istor*
Preventive
Maintenance
Maintenance
Plans and
Items
Strateg*
Sc2eduling
Planner ;roup
Measurements
8
Technical Object - Is It An Eui!"ent # $unctional %ocation or Material&
/0uipment
Can Move From Place ,o Place
Can 7e Used For )arious Functions
9eed ,o ,rac3 +ocation 5istor*
5as Manu(acturer 1 Model Details
Functional +ocation
C2anges In(re0uentl*
5as a De(ined Structural 5ierarc2*
Used ,o +ocate 6it2in Organi8ation
Material
Interc2angea&ilit*
Usage ,rac3ed &* Serial 9um&er
9
Master Data <e* /lements
Master Data Master Data
Parts +ists Parts +ists
Assem&lies Assem&lies
Mtc$ Plans Mtc$ Plans
Spares Spares
,as3 +ists ,as3 +ists
C2aracteristics C2aracteristics
Classes Classes
Drawings Drawings Activit* ,*pes Activit* ,*pes
Cost Centers Cost Centers
Cra(ts1S3ills Cra(ts1S3ills
Capacities Capacities
/0uipments1 /0uipments1
+ocations +ocations
Mtc Mtc$ $
Organi8ation Organi8ation
10
O&=ects O&=ects
Documents1 Documents1
drawings drawings
Partners1customer Partners1customer
contact contact
persons persons
+ocation +ocation
Classi(ication Classi(ication
Multi>lingual Multi>lingual
texts texts
Usage Usage
+i(e ,rail +i(e ,rail
Con(iguration Con(iguration
Counters Counters
- - ? ? @ @
Pressure Pressure
. .
-. -.
?. ?.
#. #.
@. @.
%. %.
A. A.
B. B.
Location A
Location B
x
x
x
x
x
x
x
Service Service
organi8ation organi8ation
,ec2nical ,ec2nical
Technical Object Master Data - Eui!"ent
11
Site
+ocation
5ierarc2*
Plant
5ierarc2*
Compan*
/0uip$ ,*pe
Uni0ue ID 9um&er
Detailed
5ierarc2*
RA-TWK-120-BOILER1-PUMP-012
/0uip$ +ocation
Department
Technical Object Master Data ' $unctional %ocation ' Eui!"ent Based
12
Site
+ocation
5ierarc2*
Plant
5ierarc2*
Compan*
Cu&ical
Item
Detailed
5ierarc2*
RA-TWK-005-501-501A6-Printer
4oom
7uilding
Technical Object Master Data ' $unctional %ocation ' %ocation Based
13
Process
Process
5ierarc2*
Su&>Process
5ierarc2*
Compan*
Unit Operation
Item
Detailed
5ierarc2*
RA-SULF-3-301A-DRY-PIT301M3
P:ID Diagram
Processing Step
Technical Object Master Data ' $unctional %ocation ' P(ID Based
14
Install an Eui!"ent in a $unctional %ocation
One or more pieces o( e0uipment can &e installed in a (unctional
location
/0uipment in2erits location &ased data w2en installed
4oom
Operating department
C2arge codes
4esponsi&le maintenance team
Movement 2istor* &etween (unctional locations recorded
15
F+OC +ower
Functional +ocation
5ierarc2*
/0uipment
5ierarc2*
F+OC Upper
Assem&l*
Materials
Materials
5ierarc2*
Su& /0uipment
/0uipment
)o"bined $unctional %ocation# Eui!"ent# Materials *ierarchy
16
6or3 Is
Identi(ied
9oti(ication Made
7* Customer
6or3 Order Is
Created 7* ,2e
6or3 Center Or
Mec2anic
4ecord
62at
6as Done
Maintenance
C*cle
+or, Order Processing
17
-otification .ersus +or, Order
9oti(ication
6or3 4e0uest
Captures Damage and 4epair 5istor* "using standard codes'
4ecords Downtime 5istor*
6or3 Order
Sc2eduling and Planning
Captures Cost 5istor* "+a&or : Materials'
4ecords Personnel 5istor*
Data is Arc2ived Periodicall*
18
6or3 Order Processing <e* /lements
-otification -otification
Mtc$ Plans Mtc$ Plans
User User 4e0uests 4e0uests
+or, Order +or, Order
Manage"ent Manage"ent
Material Material
4eservations 4eservations
Material Material
Issues Issues
,ime ,ime
<eeping <eeping
+a&or +a&or
4e0uirements 4e0uirements
;oods1Invoice 4eceipt ;oods1Invoice 4eceipt
Purc2ase Orders1 Purc2ase Orders1 Contracts Contracts
6or3 Orders 6or3 Orders
Purc2ase Purc2ase
4e0uisitions 4e0uisitions
19
Turnaround Scheduling Techniues
Assign Orders to a C4evisionD
9etwor3 PM OrderDs Operations
Pro=ect S*stems 6or3 7rea3down Structure
Pro=ect S*stems 9etwor3 and Activities
/xport1Import 67S to /xternal Pro=ect
Management ,ool "Primavera, MS Pro=ect'
20
+arranty $unctionality
Customer or )endor 6arranties
,ime 7ased, Condition 7ased "mileage' or 7ot2
CPop>upD dialog &ox i( e0uipment is under
warrant* w2en doing repairs$
21
+or, )learance Manage"ent
+oc3 Out 1 ,ag Out Functionalit*
Pre De(ine +ist o( +O 1 ,O Points
/nter transaction in SAP w2enE
/0uipment is read* (or +O1,O
/0uipment 2as &een +O1,O
/0uipment is read* to &e put &ac3 in service
/0uipment is &ac3 in service
4ed 1 Fellow 1 ;reen 5eads Up Displa*
Created (or nuclear power industr*
22
Maintenance Strateg!
Tie B!"e# $r %$&nter B!"e#
Li"t $' A(!i)!*)e Fre+&en,ie" -.!,/!0e"1
%!)) 2$ri3$n -PMI $r#er ,re!te# *e'$re #&e #!te1
S4i't F!,t$r -)!te ,$.)eti$n #e)!5" ne6t PMI1
+as# ,ist
Li"t $' O.er!ti$n"
E"ti!te# D&r!ti$n $' 7 $*
Re+&ire# P!rt"
Fre+&en,ie" -.!,/!0e"1
Str!te05
Fre+&en,5
O.ti$n"
Maintenance Item
E+&i.ent 8&*er
T!"/ Li"t
Str!te05
Maintenance Plan
9r$&. Ite" T$0et4er
%!)) 2$ri3$n
S4i't F!,t$r
M!inten!n,e Ite
Str!te05
Sc-edule Plan
St!rt P)!n
Re",4e#&)e P)!n
Ie#i!te %!))
M!n&!) %!))
%re!te PMI W$r/$r#er
'e$ault Call
&ori.on (
S-i$t Factor
Preventive Maintenance
23
Customer Service Module
24
)usto"er Ser.ice Module
Maintain Customer1Client /0uipment
Similar Functionalit* as Plant Maintenance Module
Increased Sales and Distri&ution Module Integration
Call Center Functionalit*
Uses Same Personnel as PM Module
Pro(ita&ilit* Anal*sis
25
SAP Integration
26
Effects of Integration on I"!le"entation and Maintenance of Syste"
Integrated pro=ect plan wit2 ot2er SAP modules
C2anges in PM Con(iguration A((ect Ot2er Modules
4egression testing o( all modules
Ot2er modules a((ect PM
Corporate wide c2ange control procedures
Corporate maintenance o( 2ardware 1 so(tware
)isi&ilit* o( PM details to corporate organi8ation
Integration vs$ C7est o( 7reedD
Inter(aces (or data trans(er not re0uired
SAP corporate sta&ilit*
Continued so(tware development
American SAP UserDs ;roup "ASU;'
+imited a&ilit* to modi(* &e*ond &uilt In con(iguration
Customer exits &uilt into man* screens
Additional ta&les can &e &uilt
A7AP and ta&le modi(ications strongl* discouraged
27
Integration Points
FI1CO > Accounting
General Ledger Codes
Cost Centers
Activity y!es
Co"!any Codes
#lant Codes
$ettle"ent %&les
$ettle"ent Codes
Cost %e!orts
'&dgeting
Accr&als
(nvoice )eri*ication
Acco&nts #aya+le
AM > Asset Management
Asset ,asters
Lin-ed to ./&i!"ent
54 > 5uman 4esources
."!loyee 0&"+ers
$ta**ing 1rgani2ational 3de!art"ent4
organi2ational &nit4 !osition4 etc5
Lost i"e 3vacation4 sic-ness4 etc5
#ayroll
$-ills and 6&ali*ication
raining
CA$ 3cross a!!lication ti"es7eet5
$7i*t $c7ed&les
PS > Pro=ect S*stem
#ro8ect 0&"+ers
9'$ 3:or- +rea-do:n str&ct&re5
$c7ed&le Large #ro8ects;&rn Aro&nds
Ca!ital .<!endit&re
(nvest"ent ,anage"ent 3'&dgeting5
Assets =nder Constr&ction
MM > Material Management
#&rc7ase %e/&isitions;1rders
#&rc7ase A!!roval
1&tline Agree"ents 3service contracts5
%eceiving
)endor ,asters
e'&siness
.<ternal $ervices ,anage"ent
,aterial %eservations
,aterial Catalog&e
$toc-ing in*or"ation
3+in +alance4 +in location4 cost4 etc>5
rans!ort 1rders
%estoc-ing 3,%#5
%ota+les;%e!aira+les
ooling
28
Integration Points
PP > Production Planning
#rod&ction #ersonnel doing
,aintenance tas-s
Cross A!!lication i"e $7eet
?o:nti"e $c7ed&ling *or
#rod&ction ./&i!"ent
&rnaro&nd $c7ed&ling
#rod&ction ooling $et&!
QM ! Qualit* Management
#&rc7ase (ns!ections
(nstr&"ent Cali+rations
ooling Cali+rations
Data 6are2ouse
?ata .<traction @o**AlineB *ro" $A#
C&sto" %e!ort Generation
;eneral
.lectronic ?oc&"ent ,anage"ent
3lin- to nonA$A# doc&"ents5
Classi*ication 3&ser de*ined varia+les5
6or3 Flow
%o&ting o* as-s *ro" Gro&! to
Gro&!>
29
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e t c >
30
PM Module Implementation
31
Ty!ical Project Stages

Scope De(inition

7lue Print P2ase

9or-s7o!s (n*or"ation disse"ination and decision "a-ing
Clo: C7arting #rocesses
'&siness #rocess ?escri!tions

4eali8ation P2ase
Con*ig&ration
$cri!t :riting
esting
$ec&rity and role develo!"ent
(n*rastr&ct&re
C7ange ,anage"ent
raining

;o +ive
?ata Load
C&tover
=ser $&!!ort
32
I"!le"entation Tea"

Management Steering Committee

Full ,ime ,eam Mem&ers

ec7nical 1+8ect $tr&ct&ring ; ?ata Clean&! ; Loading
9or-order #rocessing
#reventive ,aintenance
,%1 ,aterials $tr&ct&ring ; ?ata Clean&! ; Loading

Part ,ime ,eam Mem&ers

./&i!"ent .ngineering
,aintenance $c7ed&ler
raining
C7ange ,anage"ent

SAP Pro=ect Personnel

$ec&rity
A'A#
'atc7 Eo+s
ec7nical (n*rastr&ct&re
%egression esting

SAP Plant Maintenance Consultants

Data Conversion ,eam ! Legacy $yste" ?o:nload4 Cield $&rvey4

Clean =!4 ?ata Load

Part time A7AP programmer ! $7o! !a!ers design4 c&sto"

&!load !rogra"s4 c&sto" re!orts>
33
Ty!ical MS Project Plan
34
SAP Infrastructure
Sand&ox client (or concept testing
Development client (or integration and unit
testing
Qualit* assurance client (or s*stem testing and
c2ange control
,raining client (or training exercises
Production client
Production &ac3up client
35
36
37
Data )on.ersion
+egac* s*stem download
Determination o( data to &e captured in SAP and mapping to
SAP Fields
Develop SAP classes and c2aracteristics
Field veri(ication o( data
4ecords room supplement o( legac* data
Data cleanup "MS Access'
Data upload testing and veri(ication
Data upload to production
Using SAP (unctionalit*
Using custom upload programs
Using t2ird part* scripting program
38
Data )on.ersion /!load $lo0chart
L$,!ti$n"
P#n W%"
AB% In#=
%$. Are!
E.)$5ee
Re,$r#"
MRO M!"ter"
FLO%"
E+&i.
BOM"
TL L$n0 Te6t
Fi)e"
Str!te0ie">
P!,/!0e"
T!"/ Li"t"
Ite"
P)!n"
St0 Bin"
M!"ter D!t!
P)!n= 9."
?en#$r"
P&r,4= In'$
PM W$r/ %ntr"
MRO Pri,e"
MRO St$,/
St!t&"
8&*er
R!n0e"
%4!r!,teri"ti," E@ %)!""e"
E@ %4 ?!)&e"
E+ T5.e"
Me!"&rin0 Pt"
%$n'i0
A,ti(it5 T5.e"
WO B!t,4
Sett)eent
PMO D!te
M$nit$rin0
WO B&"ine""
%$.)eti$n
%!te0$r5
A S&* %!t
T!*)e
Pr$'it
%enter"
A,ti(it5 P)!nnin0
39
De.elo! 1ole Based Security Profiles
7* de(ault SAP allows no access to transactions1screens$
Implementation team develops lists o( transactions re0uired (or eac2
=o& role$
Multiple =o& roles can &e assigned to individual user IDs
Additional securit* can &e de(ined &* plant code, e0uipment o&=ect
t*pe, wor3 order t*pe, etc$
Securit* testing covers &ot2 allowed and un>allowed transactions
40
Key Design Points
Plant Structure
,odels yo&r cor!orate and "aintenance str&ct&re
Functional +ocation Structure
Location +ased or !rocess +ased 3!rod&ction and engineering in!&t also5
/0uipment
%e/&ire"ents to +e a !iece o* e/&i!"entF !&rc7ase cost4 7istory trac-ing
6or3center Structure
Cra*t +ased4 sel* directed :or- tea"s4 !lanner gro&!s
,as3 +ists
./&i!"ent or C&nctional Location4 "&ltiAo!eration4 "&ltiA!ac-age
Maintenance Plans
$ingle or "&lti ite"s !er !lan4 ti"e +ased or e/ +ased
M4O Items
$earc7ing strategy4 ,%# y!es
Data +oading
Legacy $yste"s rans*er4 #rogra""ed &!loads or "an&al4 c&tover ti"ing
41
SAP Training )ourses

PM Overview ! @ da*s

Structuring and Managing ,ec2nical O&=ects ! ? da*s

Preventive Maintenance and Service ! ? da*s

Maintenance Processing ! Operational Functions ! ? da*s

Maintenance Processing ! Controlling Functions ! ? da*s

6or3 Clearance Management ! ? da*s

Document Management ! ? da*s

Classi(ication ! ? da*s

Cross Application ,ime S2eet ! - da*s

42
Questions, Discussion, Follow Up Actions
43
Appendix E PM Module Screen Captures
44
SAP PM Menu
45
$unctional %ocation Structure
46
Eui!"ent Master 1ecord - 2eneral Tab
47
Eui!"ent Master 1ecord ' Organi3ation Tab
48
)lassification ' Assign Eui!"ent to )lass
49
)lasses - )haracteristics
50
Measuring Points
51
+or, )enters
52
-otification +or,
1euest
53
-otification '
*istory 1ecording
54
+or, Order '
*eader
55
+or,order '
O!erations %ist
56
+or,order '
)o"!letion
)onfir"ation
57
+or,order '
-et0or, %in,age
58
%ist Edit
Search Screen
' +or, Orders
59
%ist Edit
-1esults
60
%ist Edit
-1esults
)usto"i3ation
61
Multi-%e.el %ist Edit
-Selection Screen
62
Multi %e.el %ist Edit
- 1esults Screen
63
)a!acity Planning
- Menu O!tions
64
1e!orting Syste" - Selection
65
1e!orting Syste" - 1esults
66
Tas, %ist
- *eader Screen
67
)reate Tas, %ist
-O!eration 4ie0
68
Maintenance Plans
- Single )ycle
69
Maintenance Plans
- Single )ycle
Additional Data
- Scheduling
70
)onfiguration
Menu
71
)onfiguration -ode