SAP S/4HANA Implementation Plant Maintenance Overview

SAP S/4HANA Implementation

Plant Maintenance OverviewMay 2019

© 2019 Deloitte Consulting Southeast Asia

Agenda

Plant Maintenance Overview

Organisational Structure

Business Processes

Integration with other modules

Plant Maintenance Overview

SAP Plant MaintenanceAs part of Logistics, SAP Plant Maintenance supports the following activities:

Inspection All tasks for determining and assessing the actual condition of a

technical object, including identifying the cause of wear and tear and deducing the consequences necessary to ensure its future use

Maintenance All tasks for delaying the reduction of the wear reserve

Repair All tasks that return a technical object to its operational state

Improvement All technical, administrative and management tasks for improving

the functional safety of a technical object, without having to change its required function

Fundamentals of Maintenance

• Check

• Measure

• Observe

• Assess

• Deduce

consequences

• Visual inspection

• Adjust

• Replace

• Supplement

• Lubricate

• Preserve

• Clean

• Functional testing

• Replace

• Restore functions

• Correct malfunctions

• Elimination of weak points

• Improved design of machines, tech. systems

• Optimized business processes

• Faster exchange of information

Overview of Plant Maintenance (PM)

4) Unplanned Maintenance

3) Planned Maintenance

1) PM Organization 2) Technical Objects5) Reporting

Overview of Maintenance Process

Raise Maint. RequestRaise Maint. Request

Review Maint. RequestReview Maint. Request

Convert OrderConvert Order

Plan OrderPlan Order

Release OrderRelease Order

Procurement/ WarehouseProcurement/ Warehouse

Schedule OrderSchedule OrderMaintenance ExecutionMaintenance Execution

Time ConfirmationTime Confirmation

Technical CompletionTechnical Completion

Settlement/ Close OrderSettlement/ Close Order

Maintenance

Request

3

Planning

SchedulingExecution

4

2

1

6

5

Completion

Confirmation

Notification

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CorrectiveWork Order

Mavin Project | SAP S/4HANA Implementation 7

Organisational Structure


Company Code

Maintenance Plant

Work Center

MAVIN

Planning Plant

Planner Group

Pla

nt

Main

ten

an

ce

Team 1

MECHANIC

Team 1

…

Planner Grp. Elec.

PG1

Planner Grp. Mec.

PG2

Planner Group

…

Planner Group

…

Team 2

ELECTRIC

Controlling Area /

Chart of Account

MAVIN

Work Center

…

Organization Levels in Plant Maintenance

Hanoi Hưng Yên 2 Nghệ An Bình ĐịnhĐồng ThápHưng Yên 1

Hanoi Nghệ An Bình ĐịnhĐồng ThápHưng Yên 1

Planner Group

…

Planner Group

…


Plant-Specific and Cross-Plant MaintenanceFor business processes in plant maintenance, you need to differentiate between order planning and execution in the same plant and order planning and executionin different plants:• Plant-Specific Maintenance: Plant-specific planning is done in the maintenance plant.• Cross-Plant Maintenance: Multiple maintenance plants are assigned to a planning plant.

Maintenance Requirement

Plant 2000


Plant 1000

Planning of Maintenance Requirement

Spare Part Storage


Work Center Work Center

Work Center Work Center Work Center

Material

Plant 1100


Work Center

DefinitionDefinition

UsageUsage Work centers are used in orders / task lists.

A work center is an organizational unit where

work can be carried out.

Scheduling Default ValuesCosting

2200123

2323

Capacity Planning

Cap

acit

yLabour

Functions


Master Data


High Level Plant Maintenance Process

Maintain Master Data

Maintain Work Center

Maintain Functional Location

Maintain Equipment

Maintain BOM

Maintain Catalog

Analyse Work

Reports

PM Corrective/ Unplanned

Maintenance

Notification Creation

Work Order Creation

Work Order Execution &

Closing

PM Planned Maintenance

Preventive Maintenance

Planning

Schedule Plan

Work Order Generated

Automatically

Work Order Execution &

Closing


The key elements of Plant Maintenance consist of master data and transactional processing

PM Basic Data Overview

Equipment

Notification

Maint. Order

Maintenance Plan

ArbeitsplanTask list

TskLstGrp C1

10 Center 1

20

30

Functional Location

Structuring of technical systems Maintenance processing

Master Data Transaction Data

Confirmation

Bill of material

Catalog


Production Layout Example

Administration

Station 3

Station 1 Station 2

Station 4

Paint Booth DryPreparation

Trim 1 Trim 2

L e v e l 1 – P l a n t C o d e

Facilities

Mixing

L e v e l 2 – S h o p C o d e

Welding Shop

L e v e l 4 – W o r k s t a t i o n

L e v e l 3 – L i n e S e g m e n t

Assem

bly

Paint Shop

Office

Line 1

XXXX XX XX XXXX

3001

(Plant)

G1

(GA Shop)

T1

(Trim 1)

01

(Wkst 1)

SAP Representation

3001-G1-T1-0100

Functional Location Coding of Maintenance Site

Plant Code Shop CodeLine Segment

Code

Workstation

Code


Technical Object StructureTechnical object structure are comprised of 4 elements:

Functional Location

Equipment

Bill of Materials (BOM): Assembly BOM, Equipment BOM, Funct. Loc. BOM

BOM Component

3001-G1-T1 Trim 1

3001-G1-T1-02 Station 02

2100000000

52000020

51000002

51000020

Assembly BOM

BOM Component

BOM Component

Casing

Pump SIHI 200

Chassis Liner

Main Bed Assembly

3001

3001-G1

Plant

General Assembly 1

Plant Code

Production Shop

Production Line

Workstation

Equipment

Functional Location: Functional locations are hierarchically ordered

structure that represent a plant, technical system, building, or part thereof, where

equipment can be installed

Equipment: An individual physical object for which

maintenance tasks should be performed or recorded

Able to remove and transfer to another functional location

Bills of Material Group of spare parts list, assigned to each

individual piece of equipment There are 3 different BOM Categories:

(1) Assembly BOM(2) Equipment BOM

(3) Functional Location BOM

BOM Component (Spare Part) Spare part used to replace when the part is

damaged


Functional Location

Functional locations are hierarchically ordered structures that represent a technical system, building, or part

thereof according to the following criteria:

Spatial: “building 1”, “building 2”

Functional: “hydraulic press”, “mechanical press”

Process-oriented: “press”, “body”, “paint”, “assembly”, “vehicle audit”

Criteria for Functional Locations

• Execution of maintenance tasks• Recording of maintenance

tasks• Data collection over longer

periods• Cost monitoring by area• Analysis of usage conditions

V1 eScooter

V1-01 Press

V1-01-PRD Production

V1-01-PRD-01 Hydraulic

Press

V1-01-PRD-02 Pneumatic

Press

V1-02 Body

V1-03 Paint

V1-04 Assembly

V1-04-ADM Administration

V1-04-PRD Production

V1-04-PRD-01 Production

Line 1

V1-04-PRD-02 Production

Line 2


Functional Location Structure Indicator

Edit mask XXXX-XX-XX-XX

Hier. Level 1 -2 -3 -4

A = Alpha

N = Numeric

X = Alphanumeric

Functional location structure indicator defines:

the naming convention and

hierarchy levels of the plant structure.

User has to refer to a structure indicator to create a functional location.

Level Edit Mask Type Description

Level 1 XXXX Alphanumeric Plant

Level 2 XX Alphanumeric Process/Shop

Level 3 XX Alphanumeric Production Line

Level 4 XX Alphanumeric Workshop

Functional Location Label Level

3001 Car Plant

3001-G1 GA 1 Shop

3001-G1-T1 Production Production Line

3001-G1-T1-01 Station 1 Workshop

3001-G1-T1-02 Station 2 Workshop

… … …


Equipment

A piece of equipment is an individual object that is to be maintained independently, such as pumps, motors,

and vehicles for which:

maintenance tasks are to be performed and recorded

can be installed at functional locations

can be linked to a material if there is a need for inventory management

Criteria for Equipment

• Management of individual data• Recording of maintenance

tasks• Object-based recording of

costs• Evaluation of technical data• Recording of usage times

V1

Usage list

03/01/18-15/01/18 3001-G1-T1

V1-01-PRD-01 V4-02-PRD-01

15/01/18-31/22/99 3001-G1-T2

Equipment Master Record

General

Location

Organization

Structure

• Location data • Address

• Object type, Class• Manufacturer data…

• Higher-level function location• Superior equipment

• Account assignment data • Responsibilities


Bills of Material

A bill of material

is a complete, formally structured list of the components of a product or assembly,

contains the description and object number of each component, the quantity and unit of measure.

In plant maintenance, BOM is used for the following two purposes:

Structure description

Spare parts planning

Worm Gear Assembly # Parts Qty.

1 Body 1

2 Worm wheel 1

3 Worm shaft 1

4 End bell 1

5 Flange 1

6 Seal cover 1

7 Bearing A 2

8 Bearing B 2

9 Oil seal A 1

10 Oil seal B 2

11 O ring 1

12 Oil plug 1


A task list consists a series of standard maintenance operations that can be used repeatedly for different

maintenance orders. Three types of task lists are available:

Equipment task list

Functional task list

General maintenance task list

Task list

Operation 20

Operation 10

Material components

Production Resources

and Tools

Task list group

Work center Texts Control data Times

V1-01-PRD

Functional Location

20001001

Equipment

PRESS_WTG

(General)


Transaction Data in Plant MaintenanceElements of maintenance process are:

Notification

Maintenance Order

Confirmation

Notification

What is the problem?• Where?• What time?• How long?

What kind of damage/ how did it fail? (eg. cracked, broken, burnt)

What is the cause/why did it fail? • Wear and tear• Corrosion• Lubrication failure• Fatigue

Maint. Order

What needs to be done?• Operations• No. of people• Planned hours

What component is required?• Stock spare part• External material• External Services

How much will it cost?• Planned Cost

Confirmation

Confirmation Data:• Actual Work


Business Processes


PM Work Order Process

NotificationMaintenance

Plan

Internal Labor

External Service

Non-Stock Spare Part

Stock Spare Part

Work Order

Operation

ComponentPR

Reservation

Confirmation

POExternal Service

PONon-Stock Spare Part

Good ReceiptExternal Service

Good ReceiptNon-Stock Spare Part

Good Issue

MaterialAvailability ?

PR

Yes

No

Good ReceiptTo Store

POStock Spare Part

MRP

DocumentTechnicalHistory

TECO

Settlement

Close

Maintenance Process

Related Process

Legend

Automatic Process


Corrective and Unplanned Maintenance Process

PM process flow involves following processes, activities and roles

Request

Planning

Scheduling

Execution

Confirmation

1

2

3

4

5

Notification

• Technical object

• Description

• Date

• Malfunction

• Work to perform

• Internal/External

Resources

• Material

• Tools

• Order Release

• Paper Printout

• Capacity Leveling

• Availability Check

• Material Withdrawal planned/unplanned

• External Procurement

• Time Confirmation • Techn. Confirm.

Maint. Order

Maint. Order

Confirmation

Requestor

Maintenance Planner

RolesContentProcess Steps

Maintenance Planner

Technician /

Warehouse Clerk

Maintenance Planer/

Supervisor/ Controller

Technician /

Maintenance Planner

CompletionMaint. Order

• Techn. Completion • Order Settlement6

Maintenance Planner


Data Captured in Notification

Notifications record important information about maintenance requests: what, where, when and how the

request is to be done.

Request

Planning

Scheduling

Execution

Confirmation

1

2

3

4

5

Notification

Maint. Order

Maint. Order

Confirmation


6

Notification

• Date / Time / Reported by

• Description

• Maintenance object: Functional Location, Equipment

• Long text

• Breakdown info

• Object Part

• Damage

• Cause of damage

Activities• Activity

• Execution factors

Tasks• Dates

• Task description

Notification ItemsNotification Items

Catalog

Process Steps


Catalog

Catalogs are used when maintaining notifications for the coded entry of results and activities.

Catalog Types

• 2 for Task

• 5 for Damage causes

• A for Activities

• B for Object part

• C for Damage

Codes

Code groups

Catalog Type: C - Damages

Code Group: MOT/01 – Engine damage

Code Short text

1000 Broken

1001 Overheated

1002 Cable Snapped

1003 Unbalanced

Code Group: PM01 – General damage

Code Short text

1000 Broken

1001 Torn

1002 Warped

1003 Leaking

Catalog Profile

restricted by

Catalog Type Code Group

5: Causes PM*

B: Object Parts PM*


Maintenance Planning and Scheduling

Maintenance Order is the main working document that manages and specifies the maintenance tasks

Request

Planning

Scheduling

Execution

Confirmation

1

2

3

4

5

Notification

Maint. Order

Maint. Order

Confirmation


6

Content:

o Scope of activities required for the maintenance job

o Identify the objects to be worked on

o Specify and plan the resources necessary

o Schedule the dates of the activities

o Capture the planned and actual costs incurred.

Planning:

Internal processing

o Internal workshops (work centers) are used to execute the work.

o Planned time and man hour costs are captured.

External processing

o External contractors are hired to perform the work.

o Purchase requests and purchase orders are raised to procure the external services.

Maintenance OrderProcess Steps


Material Planning

Materials required for the job can be planned using stocked components

ComponentAssignment

Order Release

Material Reservation

Printout(if needed)

Goods Issue

Availability

Check

Automatic

Availability

Check

Stock Material• Item Category: L


Non-stock Material• Item Category: N

Material Purchase

In-direct materials required for the job can be purchased using Non-stocked components.

ComponentAssignment

Purchase Requisition

Order Release

Goods Receipt

Invoice Receipt

Create & Release Purchase Order

CompanyInvoice


Execution

Maintenance Activities can be carried out.

Request

Planning

Scheduling

Execution

Confirmation

1

2

3

4

5

Notification

• Technical object

• Description

• Date

• Malfunction

• Work to perform

• Internal/External

Resources

• Material

• Tools

• Order Release

• Paper Printout

• Capacity Leveling

• Availability Check

• Material Withdrawal planned/unplanned

• External Procurement

• Time Confirmation • Techn. Confirm.

Maint. Order

Maint. Order

Confirmation


• Techn. Completion • Order Settlement6

Requestor

Maintenance Planner

RolesContent

Maintenance Planner

Technician /

Warehouse Clerk

Maintenance Planer/

Supervisor/ Controller

Technician /

Maintenance Planner

Maintenance Planner

Process Steps


External Processing in Plant Maintenance

InvoiceVerification

Vendor Purchasing

Maintenance

GR for Service

Purchase Requisition

Purchase Order

CompanyInvoice

ArbeitsplanMaint. Order

0010 Operation 1

0020

0030

Actual Cost

Reason for External Processing

• Lack of Qualification• Insufficient Capacities• Outsourcing• Costs

External processing means that external companies are used or orders are assigned externally for processing

pending maintenance activities.

Services


Confirmation & Completion

Technical Completion means completing the job and updating the maintenance order and notification

Request

Planning

Scheduling

Execution

Confirmation

1

2

3

4

5

Notification

Maint. Order

Maint. Order

Confirmation


6

Time Confirmation:

o Capturing costs and time against the job

Technical Confirmation:

o Create notification to record findings of the job (if needed)

Technical Completion:

o Completing the order and notification to denote the job is technically completed.

Settlement Order:

o Maintenance order costs are settled to a cost receiver through Order Settlement.

Process Steps



Preventive Maintenance is characterized by the fact that maintenance orders are planned in advance through

maintenance plans and automatically generated.

Maintenance Plan

Scheduling

Preventive Maint. Order

Execution

Confirmation

After a maintenance plan is scheduled, planned dates are created by the system.

When planned dates are due, preventive maintenance orders are automatically generated.

The required resources are already planned in the maintenance plan and are automatically scheduled for execution.

Completion


Preventive Maintenance Types

Preventive Maintenance can be scheduled using time-based, performance-based, condition-based or predictive.

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Time-basedPerformance-

basedCondition-

basedPredictive


Time-based Strategy Plan

Scheduling Data

ArbeitsplanTask list

TskLstGrp C1

10 Center 1

20

30

Maintenance Item

Maintenance Plan

3 months

Maintenance

Item

Reference ObjectResponsibilities /

Planning data

In time-based preventive maintenance, maintenance tasks are triggered after a specific time period has

elapsed


Interrelationships of Preventive Maintenance

Operations

Material

Maintenance Packages

MAINTENANCE TASK LIST

Scheduling Parameters

Maintenance Packages

MAINTENANCE STRATEGY

Object / Object lists

Maintenance Task List

Organization and Responsibility

MAINTENANCE ITEMTECHNICAL OBJECT

Functional Location

Equipment

SCHEDULE

Start Date

Scheduling Parameter

Scheduling Parameters

Maintenance Item(s)

Call Object (Orders, Notifications,…)

MAINTENANCE PLAN

Order/Notification

Automatically created by the system

Determine due date to generate maintenance call object

SCHEDULING MAINT. PLAN CALL OBJECT

Compulsory

Optional

Legend


The refurbishment business process is characterized by spare parts being held as reserves in the warehouse

There are different statuses for the spare parts (e.g., new, functional, faulty)

Refurbishment of Spare Parts

Production

Spare PartWarehouse

Refurbishment

Procurement Scrapping

ProcureSpare Parts

Functional Faulty

Refurbished To be refurbished

Can no longerbe refurbished

1 52

4

3


Integration


Integration with Other Modules

NotificationNotification

Maintenance OrderMaintenance Order

Goods IssueGoods Issue

Order SettlementOrder Settlement

CompletionConfirmationCompletionConfirmation

Purchase OrderPurchase Order

Goods ReceiptGoods Receipt

Actual Cost UpdateActual Cost Update

G/L Account UpdateG/L Account Update

PS

FI/CO

PM

MM

Project SystemProject System

Purchase RequisitionPurchase Requisition

Stock InventoryStock Inventory

Project System: is used to plan and monitor maintenance project, e.g. shut down project

Materials Management: will generate material reservation again Inventory or purchase requisition in Procurement

Financial and Controlling: Order costing will determine the repair costs in the maintenance order


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SAP S/4HANA Implementation Plant Maintenance Overview

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