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.

Overview Plant Maintenance

Technical Objects & benefits

Plant Maintenance Processing & benefits

Main Reports, Standard Analysis & benefits

Overall benefits of SAP PM

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

Functional Location

Equipment

Bill of Material

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

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

Maintenance Notification

Maintenance Order

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

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

1. Links to 1,2…n Notifications2. Commercial Functioning3. Plan Labor, Spares, External Service…..Planned Costs & Dates…..Link with MM, FICO, PS, HR, QM4. Time Confirmation of Labor, GI of Stock Material, Service PR-PO-ES, Non Stock Material PR-PO-GR, Direct Bookings by Accounts5. Settlement

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.

Display Total equipment list……………………….(IH08 / IE07)

Display Measuring points……………………………(IK07) Display Measuring Documents………………… (IK17) Display Work center list……………………………..(CR05) Display Notification…………………………………… (IW28 /

IW29) Display tasks ( Catalogue)…………………………(IW67) Display Order……………………………………………..(IW39 /

IW40) Display Operation……………………………………….(IW49) Display Maintenance Plan…………………………..(IP16) Display Maint. Scheduling over view………….(IP24 / IP19) Display task list……………………………………………(IA09)

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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

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.

MCI1-Object ClassMCI2-Manufecturer MCI3-LocationMCI4-Planner GroupMCI5-Damage

AnalysisMCI6-Object

StatisticsMCI7-Breakdown

AnalysisMCI8-Cost AnalysisMCIZ-Vehicle

Consumption Analysis

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:

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:

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.

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

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

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

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 notificationfor describing the recorded damage

► Causes of DamageThe 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.

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

· 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