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How to Create Configurable Task Lists for Preventive Maintenance

Terry Chilton-Volvo IT

[ Learning Points
Understand the basic requirements for creating configurable task lists. See a practical demonstration on the use of configurable task lists. Learn the limitations of configurable task lists.

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[ Best Practices
Ensures consistency in procedures for similar (but not identical) equipment or assemblies. Streamlines updates to task lists for multiple pieces of equipment. Makes use of existing task list operations and bills of material. Enables other facilities with like equipment to make use of the copy reference function

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[ Advantages of using Configurable Task Lists

Without Configurable Task Lists With Configurable Task Lists
S60R Maintenance Plan S60R Equipment Master Record S60R Task List S60R Maintenance Plan S60R Equipment Master Record

V60 Maintenance Plan

V60 Equipment Master Record

V60 Task List

V60 Maintenance Plan

V60 Equipment Master Record Configurable Task List

XC90 Maintenance Plan

XC90 Equipment Master Record

XC90 Task List

XC90 Maintenance Plan

XC90 Equipment Master Record

S80 Maintenance Plan

S80 Equipment Master Record

S80 Task List

S80 Maintenance Plan

S80 Equipment Master Record

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[ How it works
0010-Perform Task for V60 0020-Perform Task for S80 0030-Perform Task for XC90 0040-Perform Task for S60R Characteristic/Value Filter

0040-Perform Task for S60R

Work Order

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[ The Process Steps

*CT04 - Create the characteristics and values . *CL01- Create the configurable classes. *MM01- Create the configurable material *CU41 - Create the configuration profiles for the configurable material. IA05 - Create the configurable task list with all the operations needed for equipment . MMP1/CS01 - Create the master BOM with all materials used for all equipment . *CU41 - Create the configuration profiles for the task list *IE02 - Change the equipment using the configurable task list by referencing the master BOM in the Construct Type field and link the configurable material to the equipment. *IA06 - Link each operation in the task list to a dependency (or dependencies) to enable the filtering of operations during the work order creation process. IP04 - Create (or change) the maintenance item using the equipment and new task list. IP01- Create (or update) the maintenance plan (if using an existing item that is connected to a plan, skip this step). * Covered in this presentation
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[ Requirements
Requirement #1-All of the equipment must have the same planning plant. Requirement #2-All the tasks must use the same strategy. Requirement #3-The task list and the equipment must use the same BOM or the equipments BOM must be PM structure element of the task list BOM.

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[ Connecting the pieces/Local-Global decisions

Local Global Local

Configuration Profile for the Task List

Configuration Profile for the Material

Global

Equipment

Configurable Material
Global

Configurable Class

Local

Global

Configurable Task List

Characteristics and Values

Consider the naming/numbering strategy for each before beginning!

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[ What can we re-use?

The Maintenance Plan. The Counter The Current Maintenance Schedule. The Maintenance Item

The Planned Job Task Lists

Once all the requirements are complete, the maintenance plan can be updated by changing the maintenance item and replacing the old task list with the new configured task list.
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[ Determining the variations to build the characteristics

The most important step is to determine the different variations in the equipment that will use the task list. This can be accomplished several ways as long as the results are the same.
Model (Characteristic) S80 S60R V60 XC90 Model Year 2008 2010 2011 2009

One method is to use a spreadsheet (like the simple example above). List all the characteristics in columns and the equipment in the rows. In the corresponding cells, indicate the values for each characteristic for each equipment.

The next step in the process is to create the characteristics and their associated values.

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[ Review the Requirements for Configurable Task Lists

CT04 Create Characteristics and Values Before going into the actual steps for creating characteristics and value, it is necessary to first understand the impact they have on the ERP solution. Characteristics are used in materials management and network planning so we must be careful to ensure to segregate plant maintenance from the other business functions when it comes to master data. How do we accomplish this? First, we must maintain central control over the creation of characteristics and values for plant maintenance (meaning 1 person with a backup should have authorization). Second, we should consider using some logic to the creation of characteristics to identify them to be used for PM (for example use the prefix PM for all characteristics as in this document) and include those in a characteristic group for plant maintenance. Lets go to the transaction to review the process.

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[ Review the Requirements for Configurable Task Lists

CT04 Create Characteristics and Values After logging on to SAP, we enter the transaction code CT04. CT04-1 Next, we enter our characteristic then choose the Descriptions tab. CT04-2

Youll see this message next. Click yes to continue.

CT04-3

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[ Review the Requirements for Configurable Task Lists

CT04 Create Characteristics and Values
Next, well choose our data type format. The majority of the time, we will choose character format. If you are absolutely certain one of the other data types will be used, it can be selected. Otherwise, choose the character format. CT04-4 After choosing our data type, we will see additional fields displayed to further define the parameters based on the data type chosen. Here we choose the maximum number of characters to be used for manufacturers. Next, well enter values by choosing the values tab. CT04-5

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[ Review the Requirements for Configurable Task Lists

CT04 Create Characteristics and Values CT04-6

Next, well enter the descriptions for our characteristic. Once finished, click on the values tab.

CT04-7

For the value assignment choose multiple values since we will have more than one manufacturer for our equipment.

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[ Review the Requirements for Configurable Task Lists

CT04 Create Characteristics and Values Some key points to remember when entering characteristic values: The list will be constantly changing as you begin to use characteristics in creating your dependencies in configurable task lists. As mentioned before, central administration of this master data is recommended.

Make sure the spelling is correct in entering the values.

After entering the values, make sure to update the list by clicking on the sort button at the bottom to save the list in alphabetical order. When finished, make sure to click the save button!

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[ Review the Requirements for Configurable Task Lists

CL01-Create the Configurable Class The next step is to create the configurable class. The configurable class is the linkage between the characteristics and values and the material and configurable task lists Since we choose the values of the characteristics for the equipment based on local designs, we can include all possible characteristics for global equipment and use the same configurable class. In turn, we can create the configurable class with the intent to use it globally (no reference to plant).

CL01-1

We choose to name the class with the same number as the task list except we use an underscore and a suffix of 100.

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[ Review the Requirements for Configurable Task Lists

CL01-Create the Configurable Class Here we enter the description for the class and set the status to released. Click on the Char. tab to move to the next step. CL01-2

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[ Review the Requirements for Configurable Task Lists

CL01-Create the Configurable Class

Next, we enter each of the characteristics

This is the criteria will be defined in the columns in the excel spreadsheet (see slide 10) and subsequently created in SAP (see slides 12-14). We will need to enter all of the characteristics for the equipment that will use the configurable task list here You will select the specific values when you attached the configurable material to the equipment later. After entering all the characteristics for our class, click the save button

CL01-3

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[ Review the Requirements for Configurable Task Lists

MM01-Create the Configurable Material Next, we create our configurable material.

MM01-1

The configurable material is a global object. It can be used for similar equipment in multiple plants. Therefore, we are reusing the numbering we had for configurable class in the previous step A configurable material is not physical material when used in plant maintenance (like an IBAU assembly or HIBE operating supplies). The difference here is that we choose the material type KMAT for configurable material instead of HIBE or IBAU that will use for BOMs.

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[ Review the Requirements for Configurable Task Lists

MM01-Create the Configurable Material Next, we select the views for the material. We need to select basic data 1 and basis data 2. MM01-2

MM01-3

Enter a description for the configurable material using some naming structure that indicates the equipment type assigned to.

Enter ea for each in the base unit of measure.

Click on the basic data 2 tab to continue.
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[ Review the Requirements for Configurable Task Lists

MM01-Create the Configurable Material MM01-4

In the basic data 2 area, make sure the material is configurable box is checked.
Then, click the save button.

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Material Next, we will create the configuration profile by selecting transaction CU41. We will be creating two configuration profiles. one for the configurable material which will be linked to the equipment and the other for the configurable task list . CU41-1

As contradictory as it may seem, the configuration profile for the material will be a global setting and the profile for the task list will be a local setting.
Since the task list can only be used in one plant, the configuration profile for the task list must be plant specific.

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Material CU41-2 Lets start with the configuration profile for our configurable material by following the menu path config. profile/ create. CU41-3 CU41-4 If the configurable object is not set to material, click on the change configurable object button and select material

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Material Enter the configurable material we created in slides 19-21 in the material field then click on the overview button. CU41-5

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Material Enter the profile name . It is recommended to match the profile name with the material to keep things simple. Enter 300 (for configurable class) in the class type field and click on the class assignments button at the top of the screen. CU41-6

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Material Enter the class number created in slides 16-18 in the class field and the characteristic values. Then click the save button to save the configuration profile. CU41-7

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[ Review the Requirements for Configurable Task Lists

IE02-Add the Configurable Material to the Equipment-IE02 Our next step in the process is to add the configurable material to the equipment and choose the specific values from our characteristics. Go to transaction IE02 (equipment change) and enter the first equipment number. From the central header follow the menu path edit/view selection. IE02-2 IE02-1

Then click configuration when the dialog box appears.

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[ Review the Requirements for Configurable Task Lists

IE02-Add the Configurable Material to the Equipment Enter the configurable material number in the configurable material field and click the maintain button. IE02-4 IE02-3

The characteristics for the class should appear in the char. description column. Choose each value for the characteristic for the equipment selected by clicking on the selection box in the characteristic value field.

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[ Review the Requirements for Configurable Task Lists

IE02-Add the Configurable Material to the Equipment IE02-5

When finished, click the green arrow back button.

IE02-6

Check to see if the individual config box is checked then click the save button.

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[ Review the Requirements for Configurable Task Lists

IA05/IA06-Create/Update General Task Lists with Object Dependency (Dependencies) IA06-1

The next step in the process is to create the task list. (You can use an existing task list if desired or use the copy reference function). Were changing an existing task list in this demonstration.
The task list header is created the same way as any general task list. It is suggested to use some type of naming structure to distinguish these task lists from others (for example using a C in the group counter naming structure).
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[ Review the Requirements for Configurable Task Lists

IA05/IA06-Create/Update General Task Lists with Object Dependency (Dependencies) IA06-2 After entering all the operations, components and packages for the task list, we are now ready to enter the dependencies for each step. Note-operations that apply to all the equipment using the task list do not need dependencies. Only the operations where equipment with specific characteristics and values need to have object dependencies. To enter the dependencies, select the row for the operation and follow the menu path Extras/Object dependencies/Editor.
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[ Review the Requirements for Configurable Task Lists

IA05/IA06-Create/Update General Task Lists with Object Dependency (Dependencies) For the specific operation we choose the dependency. In this example, we want the operation to apply where the equipment pmmodelname= Mustang. If we had additional dependencies, we could use logical operators (AND/OR) . Note-Operations without dependencies will be applied to all objects as a default. IA06-3

Once all the dependencies have been entered, check for syntax errors in the source code statement by clicking the check button in the upper left corner.

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Task List
CU41-1

As with the configurable material, we now must create a configuration profile for the configurable task list. Also, as mentioned before, the configuration profile for the task list is plant specific (since the task list is plant specific). We will be able to reuse the configurable class.
Since we used this transaction for a material last time, well need to change the configurable object to a general task list.

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Task List CU41-2

Enter the created (or changed) task list number and press enter.

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Task List
Enter the profile name (you can use the same profile used for the configurable material). CU41-3

Click on the class assignments button.

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[ Review the Requirements for Configurable Task Lists

CU41-Create the Configuration Profile for Configurable Task List
CU41-4

Enter the configurable class created in steps CL01-1 to CL01-3. Click the save button

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[ Review the Requirements for Configurable Task Lists

Youre Finished!

Does it work?

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[ A final note on maintenance plan scheduling and

dependencies

Whenever you use strategy based plans with multiple packages in a configurable task list, you might see calls for operations that are not relevant for the dependency.
For example, we could have a 5 year operation to change the turbo bearings. In the maintenance plan, we would see a call even if the plan is for a non-turbo application for our dependency.

However, the dependency is applied at the work order creation and the non applicable operation is omitted from the order.
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[ Our Example
We have a fleet of 4 vehicles used at the Hagerstown Powertrain facilityA Volvo S80 Sedan A Volvo V60 Wagon A Volvo XC90 SUV A Volvo S60R We change the engine oil and filter every six months
(Package is based on the strategy in the maintenance plan)

To keep things simple, we created a maintenance plan for each vehicle with one item on each plan. We used our configurable task list for all the items
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[ Key Learnings
Where configurable task lists are most beneficial for plant maintenance. The basic process steps necessary to implement configurable task lists. The limitations for configurable task list use. The decisions necessary for naming/numbering structures in a global maintenance organization for configurable task lists.

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Thank you for participating.

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SESSION CODE: 0203

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