SAP Plant Maintenance Module End User Training

For Batch #3

March 3 , 2024
Topics covered
 SAP PM KDS and Master Data

 SAP PM Organizational structure

 SAP PM Technical structure

 Maintenance Work Center

 SAP Master Data elements (Functional Location, Equipment, Bill of

Materials (BOM) for Technical Objects, Measuring Points/ Counters,

Maintenance Task Lists, Maintenance plan & Catalogue, Code groups and

Codes)

 Création of class and classification

 SAP PM KDS and Master Data
Key Data Structure (KDS)
 It represents data which is customized according to the needs of the organization. Defined only by
the implementation team members (Consultants / Core Team Members) as an one-time activity.

Master Data
Master data is the foundation of any SAP system.
Master data is typically updated infrequently, but it is critical to ensure that it is accurate and up-to-
date.
 Some examples of PM master data include:
• Functional Location
• Equipment
• Work Center
• Measure Point / Counter
• Task List
• Maintenance Plan etc.
Cont.
SAP PM Organizational structure
SAP PM Technical structure
Cont.
Cont.
 Work center
 Usually represent one persons or a department responsible

for ensuring that the maintenance work in an order is

executed by the operations.

 It specifies where operations can be carried out and who do

so

 It is the basis for cost, capacity and target data calculation .

 We used work center to define which machine or personal

Cont..
 Work center main function

• Default values for task lists and orders

• Costing data

• Scheduling data and available capacity

Work center data
 T-code for creating Work center

• Create IR01

• Change IR02

• Display IR03

• Report Work center list CR05

 Object type

 Object Type describes the type of technical object and used for grouping of

technical objects (Functional locations or Equipment) on the basis of broad

categorization based on similar type/ usage, e.g. DG, Turbine, Generator, Squirrel

cage motor, Reciprocating pump etc.

 Object type is assigned to Technical objects and can be used for technical objects

and maintenance data evaluation by using it as a criterion for selection.

 Functional Location

 It is an organizational unit within logistics that structures the maintenance

objects of a company

 It represent the place at which a maintenance task is to be performed

 It represents System area at which an object can be installed

 Objects that can be installed at functional locations are called piece of

equipment in the SAP System

 Why functional location Created

• For execution of maintenance task

• For Recording of maintenance tasks

• For data collection over longer period

• Cost monitoring by area

Functional location master
 Functional location structure indicator

 Functional location created using structure indicator

 Structure indicator contains two fields

 Coding template:- used to control which characters may be used when a label is

assigned together and how these characters are grouped together or split

 Hierarchy level:- used to define which level ends at which characters and how many

hierarchy levels the structure may contain

 The label for functional location can comprise a maximum of 40 characters

cont
 T-code for functional location

• Create ILo1

• Change IL02

• DisplayIL03

• Display all functional location IH06

• Display structure of functional location IH01

 Equipment

• It is an individual physical object maintained as an autonomous unit

• It usually represent a single object such as pumps, motors, for which maintenance

tasks should be performed

• Equipment can be installed at functional locations

• A piece of equipment can be linked with a material , if there is inventory

management

• We can manage all types of devices as a piece of equipment (for example

production utilities, transportation utilities test equipment, production resources/tools

 Purpose of equipment created

 Management of individual data

 Recording of maintenance tasks

 Object based recording costs

 Evaluation of technical data

 Recording of usage time

Equipment master record
 Equipment category

 Machine

 Production resources and tools

 Fleet object

 Measuring and test equipment

Sub Equipments
 T-code for equipment master

• Create IE01

• Change IE02

• Display IE03

• Display all equipment IH08

• Structure IH03/IH04
 )
Bill of material (BOM

• Formally structured list of the components making up a Technical object.

• The BOM components are represented by the Material codes defined in
the SAP- Materials Management (MM) module together with the exact
quantity and unit.
• A BOM is primarily used for technical structure detailing and planning of
spare parts
• The different types of BOM used in Plant Maintenance are:
1. Functional Location BOM

2. Equipment BOM

3. Material BOM (for Assembly)

Cont..
 T-code for BOM

• Assembly for a machine

• Create IB01

• Change IB02

• Display IB03

• Functional location BOM(assembly for a place )

• Create IB11

• Change IB12
 Measuring point and counters

• Describe the physical and or logical location at which a condition is described

• For Example coolant temperature in nuclear power station after the coolant has left

the pressure vessel and the number of revolution at rotor shaft of wind turbine

• In a plant maintenance measuring point are located on the technical object in

other words on piece of equipment or functional location

• Each measuring point/counter refers to a characteristics for example

kilometer ,liter, operating hours

 Cont ..

 The characteristic of measuring point or counter determines the characteristic

unit in which measurement or counter reading are entered

 For example the characteristic ratio can have the characteristic unit percent and

the characteristic temperature can have the characteristic unit degree Celsius

or degree faharanite

 Counters represent wear and tear of technical object

 Used to accumulate the reading like operating hours, energy consumption

 T-code for measuring point and counter
T-Code for Creating measuring point and counter
• Create:-Ik01
• Change :-IK02
• Display:-Ik03
• Display all points :-Ik07

Measuring document
Create:-IK11
Change:-IK12
Display:-IK13
Display all measuring documents:-Ik17
 Maintenance task list

 Maintenance task list describes a sequence of individual maintenance activity

which must be repeatedly performed within a company

 Task list defines the series of standard operation to be performed on an

equipment

 In beles Hepp a specific maintenance work is performed on pump at regular

interval. This work consists of a series of standard operations (for example

switching off, disconnect power supply of pump and so on

Types of Maintenance task list
Maintenance task list structure
 T-code for maintenance task list
For general task list
• Create:-IA05
• Change:-IA06
• Display:-IA07
For equipment task list
• Create:-IA01
• Change:-IA02
• Display:-IA03
For functional location task list
• Create:-IA11
• Change:-IA12
• Display:-IA13
 Maintenance plane
 Maintenance plan describes the maintenance and inspection tasks to be
performed at a maintenance object
 The maintenance plan describes the date and scope the task
 Maintenance plan is used to generate a call object automatically for particular
date
 A call object can be maintenance order, maintenae notification or service entry
sheet
 Maintenance items contains the following data areas
 Planning data

 Reference object

 Task list

 interval
Cont..
Maintenance plane type
 Single cycle plans

• Single cycle plans used to manage the maintenance of machines and operational

systems which are always inspected or maintained in the same way at fixed

interval

• In this plan, the same activity is excited at a regular intervals

• Some examples of single cycle plans

1. Annual inspection of fire extinguisher

2. Generator inspection every week

3. Tunnel inspection every five years

 Scheduling parameter
 Scheduling period :-it specifies the period in which planned dates should be calculated in
advance

 Completion requirement:- If you set this indicator, the system only generates the next Call
object once the preceding call object has been confirmed.

If incase you're planning to release the second schedule, the completion requirement check box is
in marked stage, the interface will not allow you to release the schedule due to the incompletion
of first schedule.

 Start of cycle :- start date for calculating planned and call dates
 Cycle modification factor :-Maintenance cycles can be lengthened or shortened using a
modification factor.

A modification factor greater than one lengthens the cycle, a modification less than one shortens
it.
Cycle modification factor
Scheduling period
 Multiple counter plane

• used in counter-based (performance-based) maintenance.

• This type of maintenance planning is not based on a maintenance strategy.

• They have different dimensions

• For example diesel generator to be maintained on the basis of

– Number of operating hour(rpm)

– Regular inspection (weekly, monthly)

 Cont..
• The cycles for a multiple counter plan are linked with either an OR operation or
an AND operation.
• For an OR operation, a maintenance order is generated for
the earliest possible planned date. for example, every 100 tons produced or
every 50 operating hours or every two weeks, the decisive factor is which
occurs first.
• For an AND operation, a maintenance order is generated for the last planned
date. If maintenance is due, for example, every 100 tons produced or every 50
operating hours or every two weeks, the decisive factor is which occurs last.
Cont..
Cycle set
 Maintenance strategy

 It is the frequencies /packages/and represent the scheduling rule for

preventive maintenance

 Provides flexibility of scheduling based on several conditions

 Define once, and then used in linking task list and maintenance plans

 Contains packages as counter milestone

 Can be set according to time (time based & according to equipment

performance (counter based

Cont ..
Time based maintenance Strategy
 Maintenance strategy scheduling indicator
 Scheduling indicator :- provides flexibility of scheduling based on several
conditions
 Time :- dates are calculated in calendar day exactly after the interval
 Time key date:- the dates are calculated from the cycle start always for the
respective key date
 Time factory calendar :-the dates are calculated in work days .
 If we create a monthly maintenance cycle (1 month =30 days) and planned dates
are calculated as follows.
 Call horizon

• The call horizon is used to define when the maintenance object (maintenance
order) is generated compared to the planned date
• Call horizon is specified as percentage of cycle
• If the total maintenance cycle is 250 day ,we define call horizon 0%,80% and
100% the system creates the maintenance order after following number of days
• 0%- immediately call the maintenance order
• 80%- call after 200 days (80% of 250 day)
• 100%- the call is made when the planned date has been reached
cont.
 Shift factor
• The shift factor is the percentage of shift that a plan can move if not completed on
time.
• For example, if a maintenance plan is due Sept. 1, but the work is not confirmed
until Sept. 5, the shift factor will determine the next plan due date.
• A100% shift on a monthly plan will move the due date to the exact day in the next
month that the work was confirmed in September (in this case, Oct. 5).
• A 0% shift will not allow the plan to move the due date. The order was completed
Sept. 5, but the due date is on the first of every month, therefore, the next due
date will be Oct. 1.
cont.
 Tolerances for late & early completion

 Tolerance defines late or early completion time period

 (+) tolerance is set for late completion

 (-) tolerance is set for early completion

 If we assign the smallest cycle in the strategy plane 30 days , we define a

tolerance of 10% in the case of early completion

 This produce a tolerance of 3 day.

 If the completion is made no more than 3 days before the planned date ,the

system does not consider this deviation when calculating the next planed date.
cont.
 Catalogs(QS41)

 It is the combination of code groups grouped together according to the

content

 We use catalog to define, manage and standardize information (for example

defect types, characteristic attributes, tasks) consistently for all client or

plant

 If we use catalogs, it s easer to record and evaluate quantitative data and

describe objects

 In catalog, information is assigned a unique alphanumeric code and an

explanatory text
 Cont..

 Codes :- description of damage ,an activity, cause of damage, object part and

task and so on

• the risk of making incorrect entries is significantly reduced

 Code groups:- a collection of codes grouped according to their related content

for example damage to vehicle ,pumps and motors or mechanical damage and

electrical damage

 Catalog :- a collection of code groups combined together by their content for

example damages and cause of damage

Cont..
Cont..
 Classification

 Classification systems has the task of describing objects using characteristics ,and

grouping similar objects in a classes to classify them and make them easier to find

 When we mange many objects we must be able to group these objects according to

features

 The structure of a classification system consists of three steps

1. defining the features( create characteristics )

2. Creating the classes and assign to characteristics to classes

3. Assigning the class to the object/equipment

Cont.
 Cont..
 T-code for Create, Change and display

 CL01

 CL02

 CL03

 T- Code for create, Change &display of Classification

 CT04
Thank you