4.3 - Maintenance Processing V2.0
4.3 - Maintenance Processing V2.0
4.3 - Maintenance Processing V2.0
Dibakar Thakur
IBM INDIA PVT. LTD.
Project UNIFY
Customer
Cyient Ltd
Name
Document
Name 4.3_Maintenance Processing _V2.0
2 Master Scenario
3 Process Coverage
Process Coverage Asset/Equipment Installation
Manage Asset/Equipment
Breakdown Maintenance
Preventive Maintenance
Calibration of Test Equipment
Spares Management
4 Best Practices
Best Practices SAP S4/HANA best practices for Plant Maintenance applicable for Cyient manufacturing plants are
mainly as below -
Breakdown Maintenance – validate the equipment and create Notification to capture initial
breakdown information and then create Maintenance Order, plan labor and material cost,
release the Order and print out the Order copy; Time confirmation and goods movement to
post actual cost to Order; update Notification with breakdown information and TECO the
Order; settle the cost from the Order to Equipment Cost Center and finally business
completion of the Order.
Preventive Maintenance – Create Task List and Maintenance Plan with right maintenance
strategy avoiding of creation of multiple plans of the same Equipment. Deadline monitoring of
the Plans to create and auto-release the Preventive Maintenance Order. Labor and materials
planned in Task list will come to order automatically, reduces the planning time of the
Maintenance planner. Book time confirmation and goods movement and TECO the Order.
settle the cost from the Order to Equipment Cost Center and finally business completion of the
Order
In addition to the above, Test Equipment Calibration, Spares management, Corrective
maintenance, maintenance cost analysis, Breakdown analysis etc are recommended as part of Sap
S4/HANA best practices.
5 Proposed Solution
Proposed Solution The below is Proposed Solution with 1. Master Data 2. Process flow diagrams & description 3.
WRICEF objects included in the solution and Automation plan if any
Below master data are primarily important for carrying out all the maintenance process detailed under section 5.2
Functional Location
Equipment
Work Centre
Material
Maintenance Task List
Maintenance Plan
Document Info Record
Master Inspection Characteristics
New Asset
Installation request
Create New Like Asset to the Create Maintenance Create and Release Add Tasks to
Equipment Master Equipment Master Notification Maintenance Order Notification
IE01 IE02 IW21 IW21, IW31 IW22
Order
Output
Time Confirmation of Technical Completion of Settle the Actual Cost of Business Completion of
Maintenance Order Maintenance Order Maintenance Order Maintenance Order
IW41, IW42 IW42, IW32 KO88 IW32
Order
Output
Technical Completion of Work Settle the Cost of the Work Business Completion of Work
Analyse Breakdown history of
Order (TECO) Order Order
equipment
IW42, IW32 KO88 IW32
Order
Output
Technical Completion of Work Review Document flow of Settle the cost of the Business Completion of the
Order (TECO) Preventive Maintenance Order Maintenance Order Maintenance Order
IW42, IW32 IW32 KO88 IW32
Create Master
Create Maintenance Create Maintenance Schedule Maintenance Release
Inspection
Plan for Calibration Task List Plan Calibration Order
Characteristics
IP01 IA05,IA01,IA11 IP10, IP30 IW32
QS22
Order
Output
Workflow -
o Trigger Notification Task Workflow to Maintenance, Production, Engineering and Quality Teams
for New Asset Installation, which will enable the respective teams to complete the necessary
Asset Installation checks and approvals before the asset becomes ready for use.
Reports – Not applicable; all standard SAP reports are available to meet Business requirement.
Conversions
o Upload program will be required to load the master data - Functional Location, Equipment, Plan,
Task List, Material master etc.
Enhancements - Not applicable; all standard SAP process will suffice business requirement excluding the
Workflow and Forms requirement.
Forms
o Maintenance Work Order Output needs to be developed as per business requirement which will
be confirmed by business.
Currently asset maintenance process are excel-based, carried out manually in all manufacturing plants of
Cyient groups. Analysing Equipment breakdown history, maintaining preventive maintenance calendar,
maintenance cost analysis, availability of critical equipment, calibration of test equipment etc. are all
manually maintained at present in Excel spreadsheet; These all manual process will be automated by the
usage of SAP S4/HANA Plant Maintenance system.
6 Gaps
Gaps Currently for new asset/equipment Installation in DLM plants, maintenance team face the
challenge of co-ordinating the installation checks and approval with other departments like –
Production, EOHS, and Engineering etc. They note down the installation check parameters
details manually in the MNT-F-08 Installation Qualification Report which is a MS-Word
document. Business requires an automated approach to co-ordinate all the installation check
and approvals processes.
7 Future Roadmap
Future Roadmap Automation can be done to use paperless maintenance process by using SAP Works Manager
Application (Syclo). With SAP Works Manager solution, user can use Mobile devices
(Android/IOS) to receive Breakdown Notification & Work Order in their handsets and they can
book material to the job from mobile and book time confirmation and all necessary job
completion details along with breakdown hours; they can attach documents to the job and
finally send back to SAP S4/HANA system. They can also do calibration inspection with the
Mobile solution. Further follow-on job can be created through Mobile if required. The mobile
solution increases the response time to attend the breakdown or any other maintenance work.
All necessary maintenance reports and historical data can be tracked and analysed in Mobile. It
increases data integrity and productivity improvement.
8 Sign-off
Business Owner
Suchitra Royroth