Workshop: Maintenance Work RequestsMay 3, 2006

Project GoalsImplement SAP Plant Maintenance system

Provide integration with Finance, HR, and MaterialsAllow enhanced scheduling and planning for work assignmentsProvide work scheduling as well as management reporting toolsAccommodate the use of mobile technology to reduce paperworkImprove automated updates to customers about the status of workImplement a Preventive Maintenance system for buildings, areas, and equipmentUtilize standard SAP functionality to collect utility usage and cost information for recharge calculations

AgendaIntroductionDiscussion of Maintenance Work RequestsPreview of Next Blueprinting SessionOther Discussion

What is the SAP Work Request Process?NotificationThis is a non-financial transaction which can be used to request work, report a problem, or record an activityIt has no visibility outside of the plant maintenance area of SAPIt may be processed via a work order, used to record non-costed activity, or closed without any work being doneIt will be automatically created by a work order, if desiredIt is frequently created by an end-user via a Web form

Why should a notification be used?To document an eventTo request work which may or may not be doneTo record a breakdown for statistical purposedTo record the technical reasons for a failure for later analysis

What information does a notification capture?Descriptive information. This includes long text which is of unlimited lengthA priority for the workA object to be maintained: A functional location (Building, Room) or piece of EquipmentContact information for the person reporting the problem or requesting workThe ability to assign a responsible person to this notificationBreakdown information, if appropriate. This is the start and end time of the breakdown. (The system will calculate Mean Time Between Failures and Mean Time to Repair.)Codes for the Damage, Cause of Damage, and Activity

What information is required?SAP only requires a description

Notification TypesMaintenance Request Used to request work, not necessarily to report a problemMalfunction Report Used to report a problemActivity Report Used to record an activity performed, not necessarily to address a request or problem. This might be used to report findings from Preventive Maintenance or to record technical information regarding the repair of a critical machine

The Maintenance Request and Malfunction Report are very similar in format and contentThe Activity Report provides for entry of more codes

Recommendation: Implement all 3 and use them as required.

What does the Priority do?It can determine the dates based upon predefined criteria for each priorityThe Start Date is calculated based on the current date. It may also include a Start Time. (Dates and times for this calculation may be in minutes, hours, or days.)The End Date is also calculated based on the current date.(Note: The Start Date and End Date may be in different units.)Each Notification type may have its own set of priorities (A Work Request could have different priorities than a Malfunction Report.)If required, different notifications types with their priorities may be established for each Plant (CPPD, MPPD, HOUS, UTIL)

What are the codes and groups?Damage CodesWhats wrongLeaking, Squeaking, Stalling, Stopped, etc.Cause of Damage CodesWhy is it not workingLoss of lubrication, low voltage, dirty, operator error, etc.Activity CodesWhat was done to correct the problemLubricated, Reset, Adjusted, Aligned, etc.

Who creates the codes?You do!

The list of codes can be short to start and can be expanded as new codes become requiredThe code groups can be specific to types of equipment (Different lists for pumps, motors, air handlers)Some suggestions follow

Possible damage codesArcingBentBowedBroken WeldBurntCorrodedCrackedEnlargedErodedFrayedLooseMissingNoisyPittedPluggedPowderyShearedShortedSmokingSplitStoppedStretchedSurgingTorquedVibratingWorn

Possible cause codesAbrasionAmps Low/HighArcingBlowing ByBolts Missing/LooseBurntConnection LooseControl OffCorrosionEmission HighErosionFloodingFlow Low/HighForce HighGroundedLeakingLubrication LowLubrication WrongPluggedPower OffPressure Low/HighSurgingTemperature Low/HighTorque HighVibratingWeld Broken

Possible activity codesAdjustedAlignedBy-PassedCalibratedChargedCleanedClearedConnectedCoupledDried-OutFluid AddedFluid ReplacedGroundedInspectedInsulatedJumperedLubricatedMeasuredReconnectedReinforcedRemovedReplacedShimmedWeldedUncoupled

Notification FieldsDetermine which fields should be eliminated because they will not be usedDetermine which fields should be required (if any)

Topics For Next Blueprinting SessionDetermine Maintenance Work Order ProcessingOrder TypesTabs and Fields on the ScreenSettlement Rules (for Recharge) Sub-OrdersMaterial Use and Availability CheckOrder SchedulingReleasing OrdersMaintenance Activity Types