Post on 27-Apr-2015
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Plant Maintenance Course
For Engineering Staff
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Agenda
PM Overview
Create Notification
Create Order
Confirm Order
View Stores Stock
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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
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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)
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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.
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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
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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
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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
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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
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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
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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
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Questions ?
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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
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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’
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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
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Agenda
Create Notification
Create Order
Confirm Order
View Stores Stock
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Objectives
At the conclusion of this topic, you will be able to:
Create a Notification
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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
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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
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Create Notification IW21
Change Notification IW22
List Editing Change Notification IW28
Demonstration & Exercise
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Agenda
Create Notification
Create Order
Confirm Order
View Stores Stock
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Objectives
At the conclusion of this topic, you will be able to:
Create an Order
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Create a Work Order from a Notification – IW21 to IW31
1. Click to go here
2. Click to go here
3. Click on Operations
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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.
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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.
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Finding a PM Work Order – IW38
1. Enter your search criteria to find the order.
2. Click Execute.
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List Editing Change Notification IW28
List Editing Change Order IW38
Demonstration & Exercise
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Agenda
Create Notification
Create Order
Confirm Order
View Stores Stock
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Objectives
At the conclusion of this topic, you will be able to:
Confirm a PM Work Order.
Complete a Notification.
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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
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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
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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
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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
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PM Order Confirmation IW41 and IW48
Cancel PM Order Confirmation IW45
Complete PM Notification IW28
Demonstration & Exercise
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Agenda
SAP Navigation
Create Notification
Create Order
Complete Order
View Stores Stock
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Objectives
At the conclusion of this topic, you will be able to:
Search and View Stores Stock Items.
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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
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Display Stock Overview - MMBE
1. Click on the material
2. Select the menu path to display your reservations
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Stores Stock Overview MMBE
Demonstration & Exercise
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Questions ?