Plant Maintenance Basics Course

Plant Maintenance Course

For Engineering Staff

Agenda

PM Overview

Create Notification

Create Order

Confirm Order

View Stores Stock

Objectives

At the end of this unit students should be able to:

Understand SAP ‘Speak’

Understand the Plant Maintenance process

SAP and Plant Maintenance

SAP is a suite of integrated modules that holds all we know about our business in one place

By using the Plant Maintenance module the business can improve maintenance programmes and make more informed decisions about maintenance routines

FIFinance

MMMaterials

Management

PMPlant

Maintenance

PSProject

Systems

CATSCross

ApplicationTimesheets

SAP ‘Speak’

Plant: is a physical location such as a factory

Functional location: is permanent or fixed location that rarely moves in a Plant such as a turbine and is identified by a unique code in SAP, for example, 1000-TUR01-LINE01

Equipment: is the equipment associated with a functional location such as a rotor, which is also given a unique SAP code, for example, 10004864

Bill of Materials (BOM): is used to group the spare parts required for maintenance work

Work Center: is the group of people who will do maintenance work; each group is identified by a unique name in SAP, for example, MECH (Mechanic), ELEC (Electrician), and CONT (Contractor)

SAP ‘Speak’

Plant Maintenance: is the SAP module used for engineering maintenance

Notification: is the initial request for maintenance in SAP and holds technical details (not costs) and also provides useful history

Work Order: is typically created from a Notification, and is used to plan the required work– Typically there are two types of work order

One for planned work (every week or month and so on), which is automatically created by the system.

And one for unplanned work (such as a breakdown), which is created manually.

Types of Maintenance Work

Two types of maintenance:

– Planned and Breakdown

In SAP these are called:

– Preventive Maintenance and Maintenance Processing

Maintenance Processing Flow

Report Need for

Maintenance

Create Notification

Plan for Labour and Materials

Create & Plan Work Order

Perform Physical Work

in Plant

Release & Print Work

Order

Document Work and Save to

History

Complete Notification and

Work Order

Report the Need for Maintenance

Maintenance requirements are identified using Notifications, for example:– Which functional location and equipment

– Description of the problem

– Priority, for example is the work urgent or can it be done during a shutdown period

Work orders are then created manually, using the Notification as a reference document

Plan for Labour and Materials

The labour and the actual work must be planned– Details of individual work times and material costs are held in the work order

– A Work Centre is assigned to each operation

The materials used for the work must be planned and made available– Stocked materials are reserved via the work order

– Non-stock materials and external services are requisitioned via the work order

Perform Work in the Plant

After the labour and materials have been planned the work order is released

Then, the system automatically:– Prints out the work order and any other required documents such as Permits for

Work

– Generates reservations for stock, which appear in the Material Management module

Document Work and Maintenance History

When the work is completed several pieces of information must be confirmed– Actual time taken to do the work

– Actual quantities of materials used

– Damage found during maintenance

– Cause of the damage

– Additional information or lessons learned

Once recorded and saved, the information becomes a part of the equipment history

In SAP both PM notifications and PM work orders are used to capture this information

Document Work and Maintenance History (cont.)

Notifications save technical history– Codes specifying the damage found

– Codes specifying the cause of the damage

– Additional comments by the workers or supervisor

Work orders save financial history– Actual labour costs

– Actual material costs

– Costs are typically attributed to Work Breakdown Structure (WBS) elements in the Project Systems module or to Cost Centres in the Finance module

Questions ?

What Will the Engineers Do In SAP?

IW21 Create a Notification

IW22 Create a PM Order from a Notification

IW28 List Change Notifications

IW38 List Change PM Orders

IW41 or IW48 Confirm PM Order

MMBE Display Stock Overview

Displaying the Structure in SAP

1. Double-click ‘Logistics’

2. Double-click ‘Plant Maintenance’

3. Double-click ‘Management of Technical Objects’

4. Double-click ‘Functional Location’

5. Double-click ‘Structural Display’

Display Structure List – IH011. Enter 3016 (this is the top level)

4. Click Execute to go here

2. Enter 5 (to see five levels below)

5. Check these symbols to expand and collapse the levels

3. Select the checkboxes shown here

Agenda

Create Notification

Create Order

Confirm Order

View Stores Stock

Objectives

At the conclusion of this topic, you will be able to:

Create a Notification

Create Notification – IW21

1. Enter type (Z1)

2. Click to go here

3. Enter description

4. Click to search for equipment or enter if known

7. Click if a breakdown, If not, leave empty

6. Enter dates or accept defaults

9. Save

5. Enter more detail about the malfunction

8. Enter work center

Finding Notifications – IW28

1. Enter selection criteria

3. Click a button to select one or more notifications (you can also double-click on the required notification).

2. Click to go here

Create Notification IW21

Change Notification IW22

List Editing Change Notification IW28

Demonstration & Exercise

Agenda

Create Notification

Create Order

Confirm Order

View Stores Stock

Objectives


Create an Order

Create a Work Order from a Notification – IW21 to IW31

1. Click to go here

2. Click to go here

3. Click on Operations

Plan a Work Order – IW31 or IW32

2. Click to go here. 1. Enter estimated hours in ‘Work’ and number of people doing the job in ‘Number’.

3. Click to go here and select the spares you need to do the job.

Print Work Order Documents

2. Print the order and material slip

1. Click to Release the order

3. Select the documents you want to print, then click Print.

Finding a PM Work Order – IW38

1. Enter your search criteria to find the order.

2. Click Execute.

List Editing Change Notification IW28

List Editing Change Order IW38


Agenda

Create Notification

Create Order

Confirm Order

View Stores Stock

Objectives


Confirm a PM Work Order.

Complete a Notification.

Single Confirmation of PM Work Orders – IW41

3. Enter the actual hours the job took in Actual Work

1. Enter the PM work order number.

2. Click Enter

4. Click the Final Confirmation and No Remain. Work checkboxes

5. Click Save

Collective Confirmation of PM Work Orders – IW48

3. Select the order you want to confirm and then click All Actual data

1. Enter a work center or a range of work centers and plant

2. Click Execute to go here

4. Enter the Actual Work and Actual Duration

5. Click the Final Confirmation checkbox and then Save

Cancel Confirmation of PM Work Orders – IW45

4. Enter the reason you cancelled the confirmation

1. Enter the PM work order number.

2. Click Enter

5. Click the back arrow

3. Click Save

Complete a Notification – IW28

4. Enter the details about the work you did

1. Enter your search criteria to find the notification.

3. Double-click the required notification

6. Click Save

5. Enter the down time here

2. Click Execute

PM Order Confirmation IW41 and IW48

Cancel PM Order Confirmation IW45

Complete PM Notification IW28


Agenda

SAP Navigation

Create Notification

Create Order

Complete Order

View Stores Stock

Objectives


Search and View Stores Stock Items.

Find Stock for Maintenance Work

1. Click the matchcode symbol next to material

2. Select the tab Plant Material by Description

4. Double-click on the required part

3. Click Enter to display list of parts

Display Stock Overview - MMBE

1. Click on the material

2. Select the menu path to display your reservations

Stores Stock Overview MMBE


Questions ?

Plant Maintenance Basics Course

Documents

Transcript of Plant Maintenance Basics Course