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SAP PM is ERP for maintenance operations carried in the industry.Maintenance activities carried on the equipments are tracedseparately.Cost incurred is maintenance is reected separately.

Benefts o SAP PM

Reection of equipments based on various criteria in the organiation.Streamlines the maintenance operations in the organiation.All the maintenance related data is centrally located.

Analysis of maintenance operations is possible based on variouscriteria.Eventually increases equipment reliability! decreases un"anted stops# improves system performance.Enhances overall performance of plant.

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•Management of Equipments in organization.

•Business Process in Maintenace,

Corrective Maintenance Breakdown Maintenance Preventive Maintenance Safety Cyces Carried out in maintenance

•!eporting System.

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1) Structuring o Equipments Located $% &his structure "ill bebased on criteria de'ned by business users.

2) Mapping the Maintenance Operations : &o trace all the

maintenance operations based on agreed guide lines of businessusers.

!) Pre"enti"e Maintenance operations : All the preventivemaintenance operations cycles "ill be copied to SAP.

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 &estingof

data.

StartStudy of equipments # theirhierarchical structure at all

facilities

Agreed basedstructure "ill be

created( applicable toall facilities) for

furthercon'gurations.

Con'gurations forstructure of equipment

"ill be done.

*nitial master data "ill becreated in SAP for

equipment structure. +sedfor testing.

Rest of master data for "illbe uploaded in the SAP

system.

End

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Equipment

Bi## O Materia#BOM

$unctiona#Location

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$unctiona#Location

•,unctional location is anorganiational unit "ithin plant! thatstructures the maintenance ob-ects ofa company according to functional!process%related criteria.

•A unctiona# #ocation representsthe p#ace at %hich a maintenancetas& is to 'e perormed(

Criteria for ,unction location can be$unctiona# criteria  e.g.$% Pumping Station! riving +nit

Processre#ated criteria  e.g.$% Polymeriation! CondensingSpatia# criteria  e.g.$% /all! 0ocation

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Equipment

•he 'usiness o'*ect +Equipment+is an indi"idua#, ph-sica# o'*ectthat is to 'e maintainedindependent#-.

• *t can be installed in a technical

system or part of a technical system

Equipments are installed at function location or they can be installed atsuperior equipments.

 &his structural hierarchy of function location and equipments is base for all

maintenance processes that are to be carried out in SAP PM.

Ma1imum attention to be given to create this structural hierarchy carefully.

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Bi## O Materia#  BOM

•2ill of material is list of material!assemblies! sub%assemblies that groupin form structural representation oftechnical ob-ect.•2ill of material can be assigned to

equipment or function location.

 &here are three types of Maintenance 23M

•,unction 0ocation 23M% 23M items are directly assigned to ,unction0ocation.

• •Equipment 23M% 23M items are directly assigned to Equipment

•Material 23M% 0ist of 23M items that are independent of technical ob-ect!  Material 23M can be assigned to di4erent location

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.or& /enter

 &he main "or5 center usuallyrepresents one person or adepartment! responsible for ensuringthat the maintenance "or5 in anorder is e1ecuted by the "or5 center.6C can be Machines !People!Production lines .

 &he 6or5 Center is assigned to the maintenance plant.

6e have to create di4erent Main. "or5 centers based on various locations.

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Brea&do%n Maintenance$% 6hen an equipment "hich in functioningstatus! stops its function and for functioning of that equipmentmaintenance is must.

/orrecti"e Maintenance$% 6hen any fault is detected in an equipment!but it can be rectify by planning the maintenance for the same.*mmediate repair is not required.

Pre"enti"e Maintenance$% ,or smooth operation of equipment certainrepair operations7 chec5s required on equipment.

2asic maintenance operations are as follo"s! these are applicable in depart

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2rea5do"n Maintenance and corrective maintenance cycles are run in SAP onsame platform! but only "ith di4erence that corrective maintenance cycle isplanned "here as brea5do"n maintenance cycle is unplanned cycle.

Brea&do%n maintenance$% 6hen equipment gets brea5do"n! in SAP2rea5do"n maintenance order is created for same. *t is release for operationimmediately. Material is assigned to maintenance order as per requirementand ta5en from store. After completion of "or5 order is con'rmed. *f historyof brea5do"n is required noti'cation is created later for this order.

/orrecti"e maintenance:% *f some fault is detected in equipment! in SAPnoti'cation is created for that equipment. 2ased on this noti'cationmaintenance order is created. Material assignment is done. 2y planning themaintenance of equipment order is release.2oth the above mentioned business process are required in the pro-ect.

,or current pro-ect need to create separate maintenance order # noti'cation

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 &o map the maintenance operations follo"ing inputs are required8)Ma-or activities that are carried out for maintenance and have di4erent cos  E.g. electrical maintenance! mechanical maintenance! fabrications etc.9) Ma-or defects that are occurring during failure of equipments.

  E.g. bearing fail! seal bro5en! corrugation etc.:) Ma-or causes of dames.  E.g. overheating! imbalance load etc. 

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M a i n t e n a n c e 

M a i n t e n a n c e P l a n P l a n 

99

 

99

 

,unctional,unctional

locationlocation

 &as5 list &as5 list6or5 order6or5 order

. . .. . .

6or5 order6or5 order

. . .. . .

Time scaleTime scale

EquipmentEquipment

99

 

EquipmentEquipment

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 &here : "ays that are used to decide the preventive maintenance cycles

1)ime 'ase pre"enti"e maintenance$% Preventive maintenance ofequipment is done on regular intervals of time. Running or performance ofthe equipment is not consider for this type of preventive maintenance.

2)Perormance 'ased pre"enti"e maintenance$% Preventivemaintenance of equipment is done on total operating hours orperformance of equipment.

!)Both ime 0 Perormance 'ased pre"enti"e maintenance$% Sometimes preventive maintenance of equipment done on condition both i.e.time and performance "hich ever comes early. &ypical e1ample of thistype is servicing of vehicle.

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 &o map preventive maintenance of equipment in follo"ing inputs arerequired!

8)Equipments! for "hich preventive maintenance cycles to be run.

9)Strategy for preventive maintenance cycles.

:);umber of preventive maintenance orders that are to be generated perday. *t is suggested that there should not be more than 9 preventivemaintenance orders per employee per shift.

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,ollo"ing maintenance cycles are also suggested for S.3. department

1)eur'ishment Maintenance Order$% &his type of maintenance orderis carried out on material that is used as stored item but on "hichmaintenance operations are required . &ypical e1ample of this type

maintenance is! small capacity pumps7 motors. &hese equipments areused as stored material item because of their multiple use butmaintenance operations carried out on these materials.2)Saet- /-c#es or Maintenance Order$% 6hen employee needs "or5in haardous conditions! dangerous conditions or unhealthy conditions andto perform the maintenance operations safety measures are mandatory!then these safety cycles are run. &ypical e1ample of these 5indmaintenance is "or5ing "ith radioactive environment! chemical plants!"ith high volt electricity etc.

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 &o map the refurbishment maintenance order and safety cycles formaintenance follo"ing inputs are required .

1)eur'ishment Order$%• 6hich material is going to be used for these 5ind of

maintenance• /o" material valuation is to be done as these orders

are directly get settled on material! it get reected inmaterial stoc5 value.

9) Saet- /-c#es in Maintenance Order$%

• Are "e going to implement these safety cycles.• 6hat are the safety norms that mandatory during

maintenance operations.•  &ypes of permits that are used during maintenance

operations.

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An- uestions 3An- uestions 3

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