Pm key user presentation- Harith senarath/Janaka Pathmendra
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This document provides an overview of plant maintenance in SAP. It discusses the benefits of plant maintenance and ERP systems. It also outlines the key components of SAP's plant maintenance module, including master data preparation, the maintenance business process, and types of reports. The business process involves preventive and breakdown maintenance, including maintenance notifications, order processing, procurement, and cost settlement.
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Pm key user presentation- Harith senarath/Janaka Pathmendra
- 1. Plant Maintenance Key User Presentation
- 2. SAP - An E.R.P. Package Contents of PM Module Benefits of PM Implementation ERP OverviewERP Overview
- 3. What is an ‘E.R.P.’ ? Why ‘E.R.P.’ is needed ? Who are Global ‘E.R.P.’ Vendors? What is ‘SAP’ ? What is ‘Client Server’ Technology ? General QuestionsGeneral Questions
- 4. E.R.P. : ENTERPRISE RESOURCE PLANNING For managing 4M’s of enterprise EFFECTIVELY.EFFECTIVELY. MATERIALMATERIAL MACHINEMACHINE MENMEN MONEYMONEY What is an ERP?What is an ERP?
- 5. A Standard Software Package taking care of all the needs of an enterprise. ‘E.R.P.’ integrates business processes across the whole company. ‘E.R.P.’ provides & helps the enterprise to adopt latest technology & international business practices with minimum ease. Why ERP?Why ERP?
- 6. Examples of Vendors Providing ERP Packages SAP BAAN JD-Edwards Marshall People-soft ERP VendorsERP Vendors
- 7. Systems, Applications, Products inSystems, Applications, Products in Data ProcessingData Processing Walldroff, Germany. SAP Stands for?SAP Stands for?
- 8. R/3R/3 Client / ServerClient / Server COCO AMAM PSPS WFWF ISIS MMMM HRHR SDSD PMPM PPPP QMQM FIFI Integration Of PMIntegration Of PM
- 9. Overview Plant Maintenance Features of SAP PM Master Data Preparation Plant Maintenance Business Process Report Requirement Critical Success Factors OutlineOutline
- 11. Definition: Maintenance is an action required to preserve or to retain the health of equipment. Importance: Because of the increase in automation and the resulting high fixed costs of operational systems, plant maintenance plays a decisive role in the success of any business. Production system need to be available 24 hours a day in order to guarantee cost effective distribution of fixed cost Plant MaintenancePlant Maintenance
- 12. Materials Management Finance / Costing Material master Accounting Service master Order settlement Equipment Bill of material Cost center Spare parts planning Activity pricing Inventory management Purchase of materials Services and contracts Quality Management Asset Management Inspection of parts Equipment and Asset link Calibration Production Planning Human Resource PRT Scheduling Man Power Capturing Plant Maintenance IntegrationPlant Maintenance Integration
- 13. The operational systems are managed using functional locations, equipment & sub-equipment. Preventive maintenance and inspection plans which are done at a regular interval are released at a scheduled point of time. Malfunctions and other direct requirements are entered directly as maintenance notification and forwarded to the respective workshop responsible for processing. Maintenance tasks are carried out using maintenance orders. Cost captured in the maintenance order is settled against the respective production cost center. The completed maintenance notifications & orders form the basis for creating maintenance history. Plant SupportPlant Support
- 14. Malfunction, Request Activity Malfunction, Request Activity Maintenance notification what when where technical info breakdown Order creation Planning of task who when, how long which steps account assignment resources Execution withdrawal utilities procurement work steps Technical information malfunction causes objects affected activity Maintenance history Completion Task requested 1111 Order Confirmation Closing 2222 3333 4444 5555 6666 7777 8888 Operation Maintenance planning Maintenance workshop Fundamental Maintenance Processing StepsFundamental Maintenance Processing Steps
- 16. MASTER DATA MAINTENANCE PLANNING NOTIFICATION PROCESSING PM ORDER PROCESSING ( RUSH / UNPLANNED ) ORDER SETTLEMENT PM PROCUREMENT & SPARES MONITORING HISTORY & ANALYSES ContentsContents
- 17. Master Data Functional Location Equipment Catalog Profile (Object, Cause & Damage) Check List (Task List) & Plan Equipment Sub-Equipment Relation Equipment BOM Measuring Points & Counters Process Instruments for Calibration Master Data ProcessingMaster Data Processing
- 18. Technical Object Management Functional location Equipment master data Permits Partner & Addresses Object link master data Bill Of Material Location specific BOM. Equipment BOM. Assembly / Material BOM. Master RecordsMaster Records
- 19. PM Work-Center. PM Task-List -> Service sheet Functional location Equipment General Measurement Point & Counter PM Catalogues. PM Material Master External Service Master Records Contd..Master Records Contd..
- 20. A functional location is an element in a technical structure, representing an area of a Plant at which Equipment/s can be installed. Advantages of structuring functional location 1. Identifying the locations via codification logic. 2. Relationship of Functional Location with Orgnization 3. Identifying the hierarchical position in structure 4. Generating the reports. Functional LocationFunctional Location
- 21. Multilingual texts Internal note Equipment usage Classification Documents Partner/Addresses Measuring points Permits Equipment master record PM data Location data Production resources/tools data Serial number data General Data Equipment MasterEquipment Master
- 22. Advantages of BOM MATERIALS PLANNING MATERIAL/SPARES PLANNING LOCATING MALFUNCTIONS
- 23. Work CentersWork Centers It defines the group of workmen's or single person or machine or multiple machines responsible for carrying out the activity. This also indicates who is supposed to carry out the maintenance. It can be even machines.
- 24. PLANT MAINT. HISTORY PM Order •Costs •Materials •Operations Equipment Plant Area (Functional location) Notification MAINTENANCE HISTORY Notification historyOrder historyUsage list (Instll.Period) Master Records •Description of Notif. •Time data,B/D Hrs. •Machine/ Object data •Fault location,Damage •Causes, Action taken •Text,Object
- 26. Preventive Maintenance (Time / Performance Based) Breakdown Maintenance Maintenance Request / Activity Refurbishment Calibration of process instruments Capital Investments Key Business ScenarioKey Business Scenario
- 27. Scheduled Maintenance Unscheduled Maintenance Maintenance Plan Schedule Plan Create PM Orders Adjust planned dates if requ’d Maintenance Notification Manually create orders Short term planning in order Release order Execute maintenance Maint operation completion confirmation Technically complete order Record technical data in notification Complete notification Settlement Functional Flow SummaryFunctional Flow Summary
- 28. NotificationNotification OrderOrder ControlControl ProcessingProcessing CompletionCompletion History Material usage, orders, notifications, PMIS, usage list History Material usage, orders, notifications, PMIS, usage list • Technical Object • Description • Date • Malfunction •Tasks to perform • Resources int./ext. • Components • Tools • Availability check • Release order • Print papers • Material withdrawal planned/unplanned • External procurement •Time confirmation •Techn.completion • Order settlement • Techn. confirmation 44 55 22 33 11 Steps In PM ProcessingSteps In PM Processing
- 29. Purchase requisition Completion confirmation Maintenance orderMaintenance order Op. 10: Internal processing Op. 20: External processing Service confirmation Goods receipt Invoice receipt Purchase order Activity costs Activity costs Material Consumption External Processing FlowExternal Processing Flow
- 30. Creation of service specifications Determination of requirements Service acceptance Invoice verification Service entry PO monitoring Ordering process Vendor selection Quotation entry Bid invitation - User department - PM Plant maintenance - PS Project system PO Invoice ? = RFQ Procurement StepsProcurement Steps
- 31. Maintenance orderMaintenance order Internal Processing operation 10: ME 3 hours operation 20: EL 1 hour External processing operation 30: EXT 1 hour Material 2 pcs. Material ABC Costs Internal Processing: Rs 500.00 External Processing: Rs150.00 Material: Rs300.00 Total: Rs950.00 Costs Internal Processing: Rs 500.00 External Processing: Rs150.00 Material: Rs300.00 Total: Rs950.00 Cost ProcessingCost Processing
- 32. Plant wise view Maintenance Group wise view Planner Group wise view Equipment wise view Functional Location wise view Financial Period wise view Plan vs Actual cost Cost AnalysisCost Analysis
- 33. TYPES OF PM PLANNING 2) Counter based maintenance A - With maintenance strategy B - With multiple counter plan 1) Time based planning MonthMonth P1 x xP1 x x P2 x x x x x x xP2 x x x x x x x kilometerkilometer P1 x xP1 x x P2 x xP2 x x
- 34. PM Reports
- 35. List of Breakdown Notifications( Daily & Monthly) Equipment Breakdown History MTTR / MTBR / MTBF Damage Analysis Manufacturer wise Breakdown Analysis Break Down ReportBreak Down Report
- 36. Preventive maintenance schedule Preventive maintenance Performance summary Preventive maintenance feed back summary(check list) Graphical Scheduling Overview Material where used List Cost Analysis Preventive Maintenance ReportPreventive Maintenance Report
- 37. Planned (Preventive )Maintenance Cost Un-Planned (Breakdown) Maintenance Maintenance Cost ReportMaintenance Cost Report
- 38. Goods Receipt Goods Issue Spare consumption through Maintenance Order(261 Mov. type) Consumption through direct issue to cost center(201 Mov. type) Consumption actual vs. planned budget Material where used List Spare Parts ReportSpare Parts Report
- 39. Cost at Work Center level Cost of Internal Activity, External Services & Spares Actual Cost Vs Planned Budget at work center level Repairs & Maintenance BudgetRepairs & Maintenance Budget
- 40. Condition of a particular Equipment/Functional Location can be managed by Condition Based Monitoring by using Measuring Points & Counters which is created against Equipment/Functional Location (Trend Analysis), Characteristic Vs Time The Preventive Maintenance (Internal / External) schedule can be generated with the help of counters ,In case of External Processing Purchase Requisitions are generated. Condition Monitoring ReportCondition Monitoring Report
- 41. THANK YOU
Editor's Notes
- #28: This flow summarizes the basic process that happens within plant maintenance. There is a section within scheduled and unscheduled maintenance that is exactly the same. In certain instances in the scheduled maintenance process, it could happen that technical data needs to be captured. In this case an activity report notification can be raised.
- #29: The PM processing cycle consists of five steps: Step 1 is the notification of a certain malfunction or some other kind of requirement (f.ex. request of reconstruction task) Step 2 creates and plans an order based on the notification. Creating operations, making reservations for spare parts or planning of operation times are typical planning tasks. Step 3 is the order control: availabilities are checked, capacities are made available and order papers are printed. Step 4 is the processing step and includes withdrawal of spare parts from the warehouse and the processing of the order. Step 5 takes place after completion of the work and consists of the confirmation of the actucal work as well as technical confirmation concerning the condition and possible damage of the object. The order will be settled by controlling.