X72 Scen Overview en AU

Scenario Overview BP Mining V1.600

X72: Rotables Management

SAP AG 2007, SAP Best Practices for Mining V1.600 – X72 Rotables Management, 2

X72 - ROTABLES_MANAGEMENT – Overview

Highlights:

The rotable management scenario has been extended to include all the processes that are typically followed to refurbish damaged equipment

Rotables are not viewed/defined as assets

Rotable inventory is fully valued

Integration:

The corrective or preventive maintenance scenario (X70, X71) initiates the rotable management scenario when a damaged rotable is replaced

Stock valuation in MM & FI

Process Overview: Industry: MiningThe rotable management scenario consists of five independent sub-scenarios or processes. Each time a damaged rotable or repairable piece of equipment needs to be processed one of the five processes must be selected. Each sub-scenario or process is a complete process managing the repair, replacement and/or scrapping of the damaged equipment. The five rotable management sub-scenarios or processes are the following:

Equipment exchange process Internal refurbishment/repair process External refurbishment/repair process Replacement process Scrapping process


X72 - ROTABLES_MANAGEMENT – Overview

Engine Fails

Engine Replaced

Damaged Engine

taken to Store

What should

happen to the

Damaged Engine?

?

• New unit obtained from a Vendor• Scrap damaged unit and give to Vendor• Pay for new unit (discount received for damaged unit)

Equipment Exchange:

• New unit obtained from Stock• Send damaged unit to the Workshop for repair

Internal Refurbishment of Equipment :

• New unit obtained from Stock• Send damaged unit to a Vendor for repair

External Refurbishment of Equipment:

• New unit obtained from Stock• Scrap damage unit – repair not feasible• Buy new unit to replace scrapped unit

Replace Equipment:

• New unit obtained from Stock• Scrap damage unit – repair not feasible• Sufficient number of units available – no replacement

required

Scrap Equipment:

I

E

S

S

S

V

S


Materialwith valuation

category C(condition-based

valuation)

Materialwith valuation

category C(condition-based

valuation)

Valuation typeC1

$ 3,000(New)

Valuation typeC1

$ 3,000(New)

Valuation typeC2

$ 2,500(Repaired)

Valuation typeC2

$ 2,500(Repaired)

Valuation typeC2

$ 2,500(Damaged)

Valuation typeC2

$ 2,500(Damaged)

Condition-based Material Valuation


Finance

X72 - ROTABLES_MANAGEMENT – Responsibility(equipment exchange)

Business Benefits

Maintenance PlanningEngineering Management

Maintenance Operations

Tracking of damaged

(exchanged) equipment

Cost controlling and tracking

Tracking of new equipment

Life cycle cost visibility

Supply

Approve PRCreate,

Release & Place PO

Receive New Equipment

Update PR Cost

(on WO)

Settle Cost

(of WO)

Maintain Equipment

Master

Install New Equipment

Damaged Equipment Replaced

Dismantle Equipment (damaged)

Install in “Scrapped”

Location

Deactivate Damaged

Equipment

Create RFQ

Create PR

(on WO)

Notes: - In the above diagram the department responsible for the expense is generally allocated the responsibility for the tasks associated with the expense- Responsibility allocation is client specific and is influenced by several factors (e.g. skill level, organisation structure, governance, etc.)


X72 - ROTABLES_MANAGEMENT – Technical View(exchange decision)

Continues to R20

Continues to R4

Continues to R8


X72 - ROTABLES_MANAGEMENT – Technical View (equipment exchange)

Continues from R4 Continues

from R13

Continues to R14


X72 - ROTABLES_MANAGEMENT – Transaction Process Flow (equipment exchange)

IW32 Create Purchase Requisition (PR on Maintenance Order)IW32 Create Purchase Requisition (PR on Maintenance Order)

IL02 Dismantle Equipment (valuation type “Damaged” – IE02)IL02 Dismantle Equipment (valuation type “Damaged” – IE02)

IW32 Update Purchase Requisition Cost (on Maintenance Order)IW32 Update Purchase Requisition Cost (on Maintenance Order)

ME41 Create Request for Quotation (RFQ)ME41 Create Request for Quotation (RFQ)

ME21N Create Purchase Order (PO) – purchase requisition approvedME21N Create Purchase Order (PO) – purchase requisition approved

MIGO Receive Equipment (valuation type “New”)MIGO Receive Equipment (valuation type “New”)

MIGO Create Equipment Master Record & Serialize EquipmentMIGO Create Equipment Master Record & Serialize Equipment

ME22N Release and Place Purchase OrdersME22N Release and Place Purchase Orders

IQ02 Update Warranty StatusIQ02 Update Warranty Status

IQ02 Install New EquipmentIQ02 Install New Equipment

KO88 Settle Maintenance Order CostKO88 Settle Maintenance Order Cost

IH01 Install in “Scrapped” Functional LocationIH01 Install in “Scrapped” Functional Location

IE02 Deactivate EquipmentIE02 Deactivate Equipment


FinanceWorkshop

X72 - ROTABLES_MANAGEMENT – Responsibility(internal refurbishment)

Business Benefits

Maintenance Planning


Tracking of damaged & new

equipment

Manage & cost refurbishment of damaged equipment

History available for continuous

improvement


Supply(refurbishment dept.)


Install New/Repaired

Equipment

Move Damaged Equipment to

Store

Issue Damaged Equipment to

Order

Receive & Issue Materials

Create Refurbishment

Order

Plan & Approve Work

Settle Cost

Capture Feedback

Complete Refurbishment

Order

Dismantle Damaged

Equipment

Return Refurbished Equipment

Link Failure Report to

Equipment

Refurbish Equipment

Release Order & Schedule

Work



X72 - ROTABLES_MANAGEMENT – Technical View(refurbishment decision)

Continues from R3

Continues to R60

Continues to R42

Continues to R27

Continues from R49 & R64


X72 - ROTABLES_MANAGEMENT – Technical View(internal refurbishment)

Continues from R26 Continues

from R31Continues from R36

Continues to R32

Continues to R37


IW32 Complete Refurbishment OrderIW32 Complete Refurbishment Order

IW41 Confirm Labour HoursML81N Capture Service ReceiptsIW41 Confirm Labour HoursML81N Capture Service Receipts

X72 - ROTABLES_MANAGEMENT – Transaction Process Flow (internal refurbishment)

IW81 Create Refurbishment OrderIW81 Create Refurbishment Order

MB11 (261) Issue Damaged Equipment to Refurbishment OrderMB11 (261) Issue Damaged Equipment to Refurbishment Order

IW32 Plan Work, Issue Permits & Release Refurbishment OrderIW32 Plan Work, Issue Permits & Release Refurbishment Order

CM25 Schedule Refurbishment WorkCM25 Schedule Refurbishment Work

MB11 (261) Issue Materials Required for RepairIW38 Print the Maintenance Orders & Execute the WorkMIGO Receive Materials Required for Repair

MB11 (261) Issue Materials Required for RepairIW38 Print the Maintenance Orders & Execute the WorkMIGO Receive Materials Required for Repair

IQ02 Attach Workshop Failure Report to Equipment MasterIQ02 Attach Workshop Failure Report to Equipment Master

KO88 Settle Refurbishment Order CostKO88 Settle Refurbishment Order Cost

IE02 Install New/Repaired EquipmentIE02 Install New/Repaired Equipment

IQ09 Display Damaged EquipmentIQ09 Display Damaged Equipment

IE4N (202) Dismantle & Moved Damaged Equipment to StoreIE4N (202) Dismantle & Moved Damaged Equipment to Store

IW8W Return Refurbished Equipment to Stock(valuation type “Repaired”)

IW8W Return Refurbished Equipment to Stock(valuation type “Repaired”)


Maintenance order 800175Order type PM04Material ENGIN_nn CAT D400 EngineSerial number CAT021(Equipment no. 1000001)Quantity 3From C3 To C2


Must be declared asrefurbishment order in

Customizing

Actual condition before refurbishmentTarget condition after refurbishment

Quantity of parts to be refurbished

X72 - ROTABLES_MANAGEMENT – Refurbishment Order(internal refurbishment)




StockStockStockStock

C3C3C3

Stock withdrawalwith movement

type 261

X72 - ROTABLES_MANAGEMENT – Refurbishment Order – Stock Withdrawal (internal refurbishment)




StockStockStockStock

C2C2C2

Inward stock movementwith movement

type 101

X72 - ROTABLES_MANAGEMENT – Refurbishment Order –Inward Stock Movement (internal refurbishment)


Quantity Stock value

10 $ 30,000.0021 $ 52,500.009 $ 1,800.00

$ 88,900$ 2,107.50

Condition Price Quantity Stock value

C1 $ 3,000.00 10 $ 30,000.00 C2 $ 2,500.00 20 $ 50,000.00 C3 $ 200.00 10 $ 2,000.00

Stock value $ 82,000.00 Moving average price $ 2,050.00

Quantity Stock value

10 $ 30,000.0021 $ 50,812.559 $ 1,800.00

$ 88,900$ 2,065.31

Stock value before processing

Stock value during processing Stock value after settlement

X72 - ROTABLES_MANAGEMENT – Effect of Refurbishment on Stock Value (internal refurbishment)

Note: Figures are examples only.


FinanceVendor

X72 - ROTABLES_MANAGEMENT – Responsibility(external refurbishment)

Business Benefits


Supply Management



equipment

Manage & cost refurbishment of damaged equipment

History available for continuous

improvement





Equipment

Approve PR

Display Damaged

Equipment

Request Refurbishment Quote (RFQ)

Create Refurbishment

Order

Plan Refurbishment

Service PR

Settle Cost

Capture Service Receipt

Complete Refurbishment

Order

Dismantle Damaged

Equipment

Return Refurbished Equipment

Link Failure Report to

Equipment

Refurbish Equipment

Update Service PR Cost

Issue Damaged Equipment to

Order

Create, Release & Place PO

Update Warranty

Status


Store



X72 - ROTABLES_MANAGEMENT – Technical View(external refurbishment)

Continues from R53

Continues to R24

Continues from R47

Continues from R26

Continues to R54

Continues to R48


IW32 Complete Refurbishment OrderIW32 Complete Refurbishment Order

X72 - ROTABLES_MANAGEMENT – Transaction Process Flow (external refurbishment)

IW81 Create Refurbishment OrderIW81 Create Refurbishment Order

IW32 Plan Service Purchase Requisition (PR) & Select VendorIssue Permits & Release Refurbishment Order

IW32 Plan Service Purchase Requisition (PR) & Select VendorIssue Permits & Release Refurbishment Order

MB11 (261) Issue Damaged Equipment to Refurbishment OrderMB11 (261) Issue Damaged Equipment to Refurbishment Order

ML81N Capture Service ReceiptsIQ02 Attach Vendor Failure Report to Equipment MasterIQ02 Update Equipment Warranty Status

ML81N Capture Service ReceiptsIQ02 Attach Vendor Failure Report to Equipment MasterIQ02 Update Equipment Warranty Status

KO88 Settle Refurbishment Order CostKO88 Settle Refurbishment Order Cost

IE4N Dismantle & Moved “Damaged” Equipment to StoreIE4N Dismantle & Moved “Damaged” Equipment to Store



IW32 Update Purchase Requisition with Strip & Quote CostIW32 Update Purchase Requisition with Strip & Quote Cost

ME41 Request for Quotation (RFQ) for RepairME41 Request for Quotation (RFQ) for Repair

ME21N Create Purchase Order (PO) for Service – PR approvedME21N Create Purchase Order (PO) for Service – PR approved

ME22N Release and Place Purchase OrdersME22N Release and Place Purchase Orders

IW8W Return Refurbished Equipment to StockIW8W Return Refurbished Equipment to Stock


X72 - ROTABLES_MANAGEMENT – Responsibility(replacement)

Business Benefits


Supply Management



equipment

Manage procurement of new equipment

&Scrapping of

damaged equipment

Tracking of new equipment




Equipment


Store

Dismantle Damaged

Equipment


Approve Updated PR

Request for Quotation

(RFQ)

Receive New Equipment

Update Warranty

Status

Create, Release & Place PO

Create PR & Add Items


SLoc for Scrap

Deactivate Damaged

Equipment


X72 - ROTABLES_MANAGEMENT – Technical View(replacement decision)

Continues from R24

Continues to R61

Continues to R73


X72 - ROTABLES_MANAGEMENT – Technical View(replacement)

Continues from R60

Continues from R68

Continues to R69


IQ02 Deactivate Damaged EquipmentIQ02 Deactivate Damaged Equipment

ME41 Request for Quotation (RFQ) – for New Equipment PurchaseME41 Request for Quotation (RFQ) – for New Equipment Purchase

X72 - ROTABLES_MANAGEMENT – Transaction Process Flow (replacement)

ME51N Create Purchase Requisition (PR)ME51N Create Purchase Requisition (PR)

ME52N Update PR with Additional CostsME52N Update PR with Additional Costs




MB1B Move Damaged Equipment to StorageLocation for Scrapped Equipment

MB1B Move Damaged Equipment to StorageLocation for Scrapped Equipment

Manual Approve PRManual Approve PR

ME21N Create Purchase Order (PO) – for NewEquipment Purchase

ME21N Create Purchase Order (PO) – for NewEquipment Purchase

ME22N Release & Place POME22N Release & Place PO

MIGO Receive New EquipmentMIGO Receive New Equipment

MIGO Create Equipment Master RecordMIGO Create Equipment Master Record

MIGO Serialize EquipmentIQ02 Update Warranty StatusMIGO Serialize EquipmentIQ02 Update Warranty Status

MM03 Review Moving Average PriceMM03 Review Moving Average Price


X72 - ROTABLES_MANAGEMENT – Responsibility(scrapping)

Business Benefits



Tracking of damaged, new

& scrapped equipment

Supply(refurbishment

dept.)


Dismantle Damaged

Equipment


Store

Display Damaged

Equipment


Equipment


SLoc for Scrap

Deactivate Damaged

Equipment



X72 - ROTABLES_MANAGEMENT – Technical View(scrapping)

Continues from R60


X72 - ROTABLES_MANAGEMENT – Transaction Process Flow (scrapping)

MB1B (313) Move Damaged Equipment to Storage Locationfor Scrapped Equipment

MB1B (313) Move Damaged Equipment to Storage Locationfor Scrapped Equipment

IQ02 Deactivate Damaged EquipmentIQ02 Deactivate Damaged Equipment




X72 Scen Overview en AU

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