7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

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What is Preventive
Maintenance and How it works
with SAP
By Amol Khairnar / April 7, 2016 / Careers / 7 Min read

This article gives you understanding of Preventive Maintenance processing with

SAP Plant Maintenance. In Part 2, I will provide step by step guide for each of the
items provided in this article.

What is Preventive Maintenance?

Wemaintenance
Preventative protect (or PM)your
is the systematic servicing of equipment to Accept all cook

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reduce the possibility of failure and downtime. It improves upon your ROI and helps
Cookies settin
in maximum productivity in turn delivering business growth.

to your advantage
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Why Preventive Maintenance is

cookies on your device to enhance site navigation, analyze site
usage, and assist in our marketing efforts.

required & how is it helpful?

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7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

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To have standard check
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lists with operationstoOUR
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check the health of the
PRODUCT
machine periodically and optimize the maintenance schedules based on the
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April 7,results.
2016

To plan advanced procurement of components and provision of service for

any technical object in a fixed interval.

To carry out regular interval based maintenance on the technical object on a

fixed frequency.

Budgeting of resources: both material and human.

To perform tasks to maintain the target condition and to determine the

condition of a technical system.

Mass planning of Preventative maintenance of all the equipment in a section

/ area.

Maintenance activities carried out at a fixed frequency, can be planned and

scheduled using this functionality.

To identify a need of a corrective maintenance to replace a particular part of

Main machinery in order to avoid any possible breakdown

Master Data required for Preventive Maintenance execution in SAP:

Functional Location

Equipment

Work Center

Catalogs
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Maintenance Task list

privacy
Service andservice
master (for external useprocurement)
data
to your advantage
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7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

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Preventive Maintenance’s
components:
1) Maintenance Strategy (Transaction – IP11) :
It defines the criteria/rules for the sequence of planned maintenance work. It
contains general scheduling information, and can therefore be assigned to as many
maintenance task lists (PM task lists) and maintenance plans as required. A
maintenance strategy contains maintenance packages in which the following
information is defined:

The cycle in which the individual work should be performed. For instance,
every 100 operating hours, every three months, etc.)

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Extra data which could affect scheduling

privacy and use data

What are the benefits?
to your advantage
It reduces the time you need to create a maintenance:
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You do not need to create the same scheduling information for each maintenance
plan as it automatically gets fetched when you assign a strategy to a plan during

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7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

creation.
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Update scheduling information easily and quick
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When you make changes in the maintenance strategy (e.g, delete packages, change
the preliminary or follow-up buffer), the changes are also valid for the assigned
maintenance plans (they are referenced). However, the scheduling parameters are
copied into the respective maintenance plan.

2) Maintenance Items (Transaction – IP04) :

A maintenance item describes which tasks should take place regularly at
a technical object or a group of technical objects. Of course, you can assign as
many maintenance items as you want to a maintenance plan. But it will always
automatically contains at least one item. Service procurement’s maintenance plans
and those plans, which refer to an outline agreement have only one item.

Key ideas about maintenance items:

An item can only be assigned to one plan.

You must have created the maintenance item you want to assign to a single
cycle plan or multiple counter plans without reference to a maintenance
strategy.

The maintenance item you assign to a strategy plan must have the

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same maintenance strategy as the maintenance plan.

privacy and use data

How can you assign maintenance items to a plan?
to your advantage
Create a maintenance plan and then create a maintenance item directly in
By clicking “Accept All Cookies”, you agree to the storing of
that plan on
cookies byyour
entering the
device to required
enhance site data in the
navigation, tab strip
analyze site Item.
usage, and assist in our marketing efforts.
Create additional items in a maintenance plan.

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7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

Create a maintenance item without assignment and subsequently assign it to

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a maintenance plan 
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3) Maintenance Plans (IP01/IP41/IP42):

Maintenance plans describe the dates and scope of the tasks. You can create
maintenance plans for the technical objects in your company, thereby ensuring
that your technical objects function optimally. You will create a maintenance plan
for both funcional locations and equipment.

Information included in a maintenance plan:

1. Maintenance Item (Functional location/Equipment)

2. Scheduling information
1. maintenance cycle

2. maintenance strategy ( Packages sequence)

3. maintenance cycles sets in case of multiple counter plans

4. Call Horizon, Start of cycle, Shift factors etc.

Types of maintenance plans

1) Time-Based Maintenance Plan
Maintenance is performed in specific cycles for time-based maintenance planning
We protect your
(every X months). To represent simple maintenance cycles, you can create a single

privacy and use data

cycle plan. To represent complex maintenance cycles, you can create a strategy
plan based on a time-based maintenance strategy.
to your advantage
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2) Performance-Based Maintenance Plan

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With performance-based maintenance plans, you can plan regular maintenance

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based on counter readings maintained for measuring points at pieces of equipment 
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and functional locations. To represent simple maintenance cycles, you can create a
7, 2016

single cycle plan. To represent complex maintenance cycles, you can create a
strategy plan based on a performance based maintenance strategy.

Assign a counter to the maintenance plan. Maintenance takes place when the
counter for the technical object has reached a certain reading, for example, every
100 operating hours, every 100 molding cycles. The calculated planned date
depends on the counter reading at the time of planning, and the estimated annual
performance that has been defined for the counter.

Maintenance Plans Classification

Single Cycle Plans:

A single cycle plan is the simplest form of maintenance plan. You create a single
cycle plan and define exactly a time-based or performance-based maintenance
cycle, in which you specify the interval at which the maintenance plan should be
executed. It can be time based & performance based both.

Strategy Cycle Plans:

We create a strategy plan and assign a maintenance strategy in which you have

We protect your
defined the maintenance cycles (in the strategy maintenance packages). A
maintenance strategy contains general scheduling information and can therefore

privacy
be assigned and use
to as many maintenance data
plans and maintenance task lists as

to2000your& 5000 advantage

required. For Example: A maintenance task is performed on a reference object after
every 1000, operating hours
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Multiple on your device to enhance site navigation, analyze site
Plans:
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7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

Multiple counter
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maintenance. This type of maintenance planning is not based on a maintenance
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strategy. This means that you create a multiple counter plan without a maintenance
April 7, 2016

strategy.

In the multiple counter plan you create maintenance cycles and allocate counters
of equipment or functional locations with different dimensions to them, for
example, flight hours, number of takeoffs and landings, kilometers traveled. You
can also integrate time-based cycles into the maintenance plan. However, these do
not have counters. Alternatively, you can also create a multiple counter plan with a
cycle set as a copy model for maintenance cycles.

Maintenance Plans Category

Maintenance plan categories are possible based on call object generated by a
maintenance plan:
1) Maintenance Order
2) Maintenance Notification
3) Service Entry sheets

Maintenance Plans scheduling (Transaction

– IP10) :
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We schedule a maintenance plan with which the system generates maintenance

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Notification/Order for the defined cycles. For each scheduling, the system
calculates the due date (planned date) for a maintenance call object based on the

toparameters
scheduling yourandadvantage
the defined frequency like weekly, monthly,
quarterly,
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then the maintenance order of required type can be created through the notification
screen.

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7/16/23, 4:47 PM What is Preventive Maintenance and How it works with SAP

Deadline
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This function
April 7, 2016 will simplify the generation of maintenance call objects for plans.
Start the deadline monitoring at regular intervals using an internally programmed
report. The system then generates the maintenance call objects according to the
cycles defined. A start date or an initial counter reading must have been entered in
the scheduling parameters for the maintenance plan, or you must have already
scheduled the maintenance plan once.

When you run the deadline monitoring function, the system converts all the
maintenance calls, for which the call horizon has been reached, into maintenance
call objects. The system also performs a complete rescheduling of the
maintenance plan and ensures that maintenance calls are always available for the
period which you have defined as the scheduling period.

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Amol Khairnar - Certified SAP
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Professional having
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6+ years of experience in
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SAP Plant Maintenance/ EAM modules as Primary skills.- SAP integration
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expertise
April 7, 2016 in SAP QM/CS/PS/PP/MM/FICO modules. PMI-CAPM Certified. ITIL
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