Plant Maintenance

Introduction to SAP PM
The R/3 Plant Maintenance (PM) module is the application component that
provides a solution for all maintenance activities that are performed within a
company.
Data and functions of all maintenance procedures performed within a
company can be fully interconnected making this module closely integrated
with other modules like Materials Management (MM), Production Planning
(PM), Sales & Distribution (SD), Controlling (CO). Data within this module is
always kept current and processes that are necessary for Plant Maintenance
and Customer Service are automatically triggered in other areas (A purchase
requisition for non-stock material in the Materials Management/Purchasing
areas).
The openness of the R/3 System enables you to use external systems that
are integrated with the Plant Maintenance (PM) component, such as
geographical information systems (GIS), computer-aided design (CAD)
systems and supervisory control and data acquisition (SCADA) systems.
The SAP Plant Maintenance (PM) comprises activities such as inspection,
measures and establishes the actual condition of a technical system,
preventive maintenance to measure and maintain the ideal condition of a
technical system, repair to measure and restore the ideal condition of a
technical system and other measures that need to be taken using the
maintenance organization.
To fulfill these activities Plant Maintenance (PM) works with the following Sub
modules:
Management of Technical Objects: includes master data objects

such as functional locations and equipment master records.
Maintenance Processing: includes processing steps such as
notifications and work orders.
Preventative Maintenance: includes maintenance planning and
work scheduling tasks.
This makes SAP R/3s PM module to function as a computerized maintenance

management system (CMMS). So lets define properly what these types of
systems are:
A CMMS software package as properly maintains a database of information
about all maintenance operations within an organization. This information is
intended to help maintenance workers do their jobs more effectively (for
example, determining which storerooms contain the spare parts they need)
and to help management make informed decisions (for example, calculating
the cost of maintenance for each piece of equipment used by the
organization, possibly leading to better allocation of resources). The
information may also be useful when dealing with third parties; if, for
example, an organization is involved in a liability case, the data in a CMMS
database can serve as evidence that proper safety maintenance has been
performed. These types of systems are a MUST for large enterprises in order
to guarantee their work properly.
These types of packages typically deal with some or all of the following:
Work orders: Scheduling jobs, assigning personnel, reserving materials,
recording costs, and tracking relevant information such as the cause of the
problems, downtime involved, and recommendations for future action.
Preventive maintenance (PM): Keeping track of PM inspections and jobs,
including step-by-step instructions or check-lists, lists of materials required,
and other pertinent details. Typically, the CMMS schedules PM jobs
automatically based on schedules and/or meter readings. Different software
packages use different techniques for reporting when a job should be
performed.
Asset management: Recording data about equipment and property
including specifications, warranty information, service contracts, spare parts,
purchase date, expected lifetime, and anything else that might be of help to
management or maintenance workers.
Inventory control: Management of spare parts, tools, and other materials
including the reservation of materials for particular jobs, recording where
materials are stored, determining when more materials should be purchased,
tracking shipment receipts, and taking inventory.
Safety: Management of permits and other documentation required for the
processing of safety requirements. These safety requirements can include
lockout-tagout, confined space, foreign material exclusion (FME), electrical
safety, and others.
As you may see SAP has specific modules for handling all these activities
mentioned. So SAP R/3s Plant Maintenance (PM) module functions as a
computerized maintenance management system (CMMS) and is used to plan
and schedule ongoing, daily facility maintenance fully integrating with all
other SAP Modules.
PM module and PP module
The PM module is very similar to the PP module except instead of producing
a product you produce repairs to a piece of equipment or a functional
location. The links are almost identical. The orders can use task lists (routes);
each piece of equipment can have a BOM; you can have an inventory of
repair parts. You can create demand for these parts by creating orders that
require the parts. You can create outside processing demand by using the
control key in the task list, just like PP. You can create a repair plan for a
piece of equipment that creates planned demand for a future period.
MM, PM integration
The integration points of MM-PM are:
For non-stock materials requirement, purchase requisition can be

created from the plant maintenance order. PR is converted to the
Purchase order.
Whenever goods receipt is done, the cost is directly booked to the
plant maintenance order.
For stock materials requirement, reservation can be created from the
plant maintenance order and the material can be issued to the order
against the reservation.
Like materials, for services also PRs can be created from the plant
maintenance order.
With Equipment BOM, you can create a list of material through which
equipment is created or in other words you can mention the spares
that you may require during the maintenance of the equipment.
Material master record for Batch Managed material as Equipment.
Material valuation class/types for refurbishment materials as
equipment.
SAP MM Integration with Finance & Controlling (FICO)
It is integrated in the area like Material Valuation, Vendor payments,

Material costing etc. Whenever any inventory posting are done, it
updates the G/L accounts in the background.
Logistics invoice verification will create vendor liability in vendor
account immediately on posting the document. Any advance given
against the purchase order updates the Po history.
For every inventory posting there is corresponding CO document to
update profit center accounting reporting.
Finished goods costing is a link through MM & PP.
Procurement of capital item cost can be directly booked against asset
number.
SAP MM Integration with Sales & Distribution (SD)

It is integrated in the areas like Delivery, Availability Check, Stock
transfers requirements etc.
Once a sales order is created, can initiate a dynamic availability check
of stocks on hand.
When the delivery is created, the quantity to be delivered is marked as
Scheduled for delivery. It is deducted from the total stock when the
goods issue is posted.
Purchase order can be directly converted to delivery for a stock
transfer requirement.
SAP MM Integration with Quality Management (QM)
It is integrated with QM for Quality inspection at Goods Receipt, in-

process inspection.
In the case of a goods movement, the system determines whether the
material is subject to an inspection operation. If so, a corresponding
activity is initiated for the movement in the Quality Management
system.
Based on quality parameters vendor evaluation is done.

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Introduction to SAP PM

Management of Technical Objects: includes master data objects

This makes SAP R/3s PM module to function as a computerized maintenance

For non-stock materials requirement, purchase requisition can be

SAP MM Integration with Finance & Controlling (FICO)

It is integrated in the area like Material Valuation, Vendor payments,

SAP MM Integration with Sales & Distribution (SD)

SAP MM Integration with Quality Management (QM)

It is integrated with QM for Quality inspection at Goods Receipt, in-

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