SAP

PLANT
MAINTENANCE

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SAP Plant Maintenance

FI
Financial
Accounting
MM CO
Materials
Controlling
Mgmt.
PP AM
Production
Planning
PM Fixed Assets
Mgmt.

QM
Quality Plant Maintenance PS
Project
Management
HR System
Human WF
Resources Workflow

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 SAP PM - Integration
 Materials Management (MM)
 Cost Accounting (CO)
 Financial Accounting (FI)
 Asset Accounting (AM)
 Human Resources (HR)
 Project System (PS)
 Production Planning (PP)

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 PM Integrated Environment

MATE R IALS MANAG E M E NT

M a s t e r D a t a
F
Pre-defined External I
work steps Services Material
Parts/Supplies Requisitions Reporting N
Notifications A
Create
N
Planned Schedule Close and
Work
WO’s Settle WO
C
Orders Work Orders
I
Emergencies A
Labor Shop L
Special
Tools Papers
S
Preventative/Predictive
Maint. WO’s

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 SAP PM - Workflow
Master Data

Pre-defined External
work steps Services Material
Parts/Supplies Requisitions Reporting
Notifications
Create
Work Planned Schedule Close and
Orders Work Orders Work Orders Settle WO

Emergencies
Labor Shop
Special
Tools Papers
Preventive
Maint. Work Order

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Overall Process Flow:

Structure
(Technical
Objects) Preventive
Maintenance Schedule

Create Work
Notification Plan Work
Order

Parts Close Work

Perform Work
Collected Order

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 SAP PM - Master Data
JCC Technical Structure
Maintain Functional Location
Maintain Equipment
Maintain Classification
Maintain Assembly
Maintain Equipment BOM
Maintain Task List (General)
Maintain Work Center

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 SAP
KEY TERMINOLOGY

Functional Location

The Functional Location is a hierarchy (like a tree structure or

organizational chart structure) which identifies the area in a plant
site where a piece of equipment is located, where it is installed,
and where maintenance is to be tracked. It can be based on floor
plan location or on process and instrumentation diagram structure.

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 Functional Location and its hierarchy

Plant Area Building Floor

Room Location Sub location

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 SAP

KEY TERMINOLOGY

Equipment
- Individual, physical object which is to be maintained
independently. Costs, where it has been used, and repair history
are recorded

examples:
production equipment
transport equipment
buildings
maintenance equipment
utility equipment

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 SAP

KEY TERMINOLOGY

Equipment Master Record

The Equipment Master Record contains the fixed data for equipment,
the physical location of the piece of equipment, accounting data,
location where the maintenance is to be tracked and location of spare
parts.

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 SAP
KEY TERMINOLOGY
SAP

Spare Part

A Spare Part is a replacement part (pump impeller), collection of

parts (pump housing) or complete replacement unit (pump,
baseplate, motor). It is a storeroom item which can have a safety
stock, or can be ordered only when required.

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 SAP
KEY TERMINOLOGY

Bill of Materials (BOM)

A bill of materials is a list of spare parts for a piece of equipment.

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 Maintenance Structuring
Functional Locations The Plant

Unique
Equipment #

Parts Assignment
Via

Bill of Material
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 HIERARCHICAL VIEW OF
PLANT EQUIPMENT
PROCESS STEP, OR GROUPS OF
PROCESS UNIT OPERATIONS

FUNCTIONAL LOCATION OR UNIT

LOCATIONS OPERATIONS

PUMPS, MOTORS
EQUIPMENT INSTRUMENTS, ETC....

BILL OF PARTS LISTS

MATERIAL

MATERIAL SPARE PARTS

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 Task Lists Type
!
• General Task List- Ideal for plants with multiple pieces of
equipment that use routine/common applications.

•Equipment Task List- Most suitable for smaller plants

and/or operations for a specific piece of equipment.

•Functional Location Task List - Most suitable for tasks

that need to be done in an area versus a specific piece of
equipment.

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Work Centers

Definition:
A producer of work: a
production workcenter is a
production train, a
maintenance workcenter is a
mechanic or production
worker doing maintenance
tasks.

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 SAP
KEY TERMINOLOGY

Notification
A notification is the request for maintenance to be
performed on a piece of equipment within a functional
location. It is used to track damage history and activities
done on a piece of equipment. A notification can be
converted to a work order where actual work and cost
can be tracked.

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Notifications
 Purpose
 Request for work to be done
 Capture history for the equipment and the
location
 Contents
 Requester
 Short Narrative of Problem
 When the work is required
 Location/Equipment
 Cause/Damage Codes
 Activities done
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 SAP
KEY TERMINOLOGY

Work Order
The work order is used to collect cost information
accumulated from labor, material and services used.
Time and resource planing and parts ordering is done
through the work order. A work order can be created
from a notification or may be created directly.

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Work Order

 Purpose
 To assign people
 Order needed parts
 Link required tasks to the job
 Collect and track all costs to the job
 Contents
 Carries over info from the notification
 Printed workorder papers

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Preventive Maintenance in SAP
Maintenance Maintenance Maintenance
Task List Item Plan Schedule
• Maintenance •Task List Maintenance Maintenance
Strategy (Time Item Calls (creates
or Performance) workorders)
•Object List
• Maintenance (Eq or FLOC) Maintenance Schedule
Packages (how Schedule Forecast
often) (start date)

•Operations
•Personnel
•Materials
Maintenance Orders

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 KEY TERMINOLOGY SAP

PMO - “Preventive Maintenance Orders”

• Task Lists
A library of operations. It provides information on the assigned
work center and the resources required.

• Maintenance Strategies
Represent the general scheduling rules for the maintenance
tasks you want to perform. Whether the task is scheduled on
time or performance.

• Maintenance Packages
Defines the exact number of days, weeks, or months that
activities will be carried out.

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 SAP
KEY TERMINOLOGY
PMO - “Preventive Maintenance.”
•Maintenance Item
Describe which technical objects requiring maintenance, as well as,
the maintenance activities and operations to be performed.

•Maintenance Plan
Consist of Maintenance Items and a Maintenance Schedule, and is
used to determine the due dates for the maintenance operations to be
performed on the allocated objects.

•Scheduling
The system calculates the start and finish dates of orders or of
operations within an order.

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 SAP PM - Configured System
Plant PM Planning PM Workshop
2 4
3 5
Malfunction, error Order
Request Creating the order
Requesting a Execution
Activity maintenance
Planning the task
who material issue
1 task
when, for how long procuring PRTs
PM Notification what steps work steps
what account assignment
when resources
where
technical information 7
Completion
breakdown Technical information 6
breakdown
causes Completion
objects affected confirmation
activities
8 Completion

PM History
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 PM Scenarios 1: Master Data Structure

No Business Process SAP Module BPP ID

1 Display JCC Technical PM – Master data
Structure (Explain the machine
decomposition)
2 Maintain Equipment PM – Master data PM-B001
3 Maintain Functional Location PM – Master data PM-B002
4 Maintain Classification PM – Master data PM-B003
4 Maintain Assembly PM – Master data PM-B004
5 Maintain Equipment BOM PM – Master data PM-B005
6 Maintain Task List (General) PM – Master data PM-B006
7 Maintain Work Center PM – Master data PM-B007

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PM Scenarios 2: Maintenance Notification to Costs Settlement

No Business Process SAP Module BPP ID

1 Create maintenance PM – Notification PM-B008
notification.
2 Review notification list PM – Notification PM-B008
3 Convert maintenance PM – Work Order PM-B009
notification to work order.
4 Trigger stock reservation for MM – Inventory
spare parts. Management
5 Create PR and release via MM – Purchasing
release strategies
6 Convert PR to purchase order MM – Purchasing
(PO) and release purchase
order.
7 Perform goods receipt (GR) for MM – Inventory
external material only. Management

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PM Scenarios 2: Maintenance Notification to Costs Settlement
(Cont’d)

No Business Process SAP Module BPP ID

8 Goods issue of spare parts to MM – Inventory
work order. Management
9 Perform goods return of MM – Inventory
surplus spare parts. Management
10 Enter Actual Work Hour into PM - CATS PM-B014
CATS
11 Transfer actual hours to Work PM – Confirmation PM-B014
Order.
12 Record technical findings. PM – Notification PM-B009
13 Close work order technically. PM – Work Order PM-B009
14 Perform invoice verification. MM – Invoice Verification
15 Settle costs to cost center. CO – Settlement
16 Close work order financially. PM – Work Order PM-B009

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 PM Scenarios 3: Initial PM Program to Automatic Generation of
Maintenance Order

No Business Process SAP Module BPP ID

1 Review the Preventive Manual -
Maintenance program for FVM
machine
2 Maintain the maintenance PM – Preventive Maintenance PM-B010
strategies
3 Review the maintenance task PM – Preventive Maintenance PM-B006
lists
4 Maintain maintenance items PM – Preventive Maintenance PM-B013
5 Maintain maintenance plan PM – Preventive Maintenance PM-B012
6 Schedule maintenance plan PM – Preventive Maintenance PM-B012

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 PM Scenarios 3: Initial PM Program to Automatic Generation of
Maintenance Order (Cont’d)

No Business Process SAP Module BPP ID

7 Execute maintenance plan PM – Preventive Maintenance PM-B012
8 Review the generated PM – Work Order PM-B009
maintenance order Management

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 PM Scenarios 4: Plant Maintenance Information System

No Business Process SAP Module BPP ID

1 Maintenance Object class PM – PMIS PM-B016
Analysis
2 Manufacturer Analysis PM – PMIS PM-B016
4 Location Analysis PM – PMIS PM-B016
5 Planner group Analysis PM – PMIS PM-B016
6 Damage Analysis PM – PMIS PM-B016
7 Object statistics Analysis PM – PMIS PM-B016
8 Breakdown Analysis PM – PMIS PM-B016
9 Cost Analysis PM – PMIS PM-B016

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 SAP PM - Benefits

 Records History to Location and Equipment

 Captures all Costs for a Work Order
 Direct Link to Store room
 Direct Link to Purchasing
 Ability to Check for Equipment Spares
 Ability to View Work Load Capacities
 Allows for Maintenance Reporting
 Allows for Comparison of Planned and
Actual Costs
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