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Transcript of Sap Business Overview - Pm Module
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SAP PM MODULE
BUSINESS
PROCESS
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The need for Information
Vision
An Integrated, Flexible and Standardised InformationSystems architecture to position towards
fundamental competitive advantage
Current Reality Function based Organisation, Multiple stand alone packages,
Time lag between market realities and decision making
SAPfor Enterprise-wide
Transformation.
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SAP R/3 – The Integrated Enterprise
SAP
R/3
Client / Server
ABAP/4
FIFinancial
Accounting
COControlling
AMFixed Assets
Mgmt.
PSProjectSystem
IM
Investment Mgmt
IS-Oil
MMMaterials
Mgmt.
SD
Sales &Distribution
PPProductionPlanning
PMPlant Main-
tenance
QMQuality
Manage-ment
ECEnterpriseControlling
LDMLifecycle
Data Mgmt
CIN
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Navigating SAP R/3
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Navigation Topics
Logging On
SAP Window components
Using the Navigation Area
Transaction Codes
Role Based Menu
Standard Tool Bar
SAP Easy Access
User Settings
Messages
Online Help use
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Logging on
Required FieldsClient
User
Password
Language
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The SAP Window
Status Bar
Title Bar
Standard Tool Bar
Menu Bar
SAP System ID
Server
Insert/Overtype Indicator
Screen Header
Screen Body
Application Tool Bar
Screen Banner
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Using the Navigation Area
You can expand andcollapse menus in the
navigation area by
choosing the dropdown
arrows to the left of the
menu items, as in theexample below
To open an application inthe navigation area
Double-click its node
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Transaction Codes
A transaction code can be entered in the Command field.
If you precede the transaction code
with /n then the transaction is thenext screen opened in the current session.
If you precede the transaction codewith /o then a new session is openedfor the transaction. This means you then have multiple sessions.
To start a transaction in SAP 4.6, there are 4 options:
Position the cursor on the required transaction in the tree structure and pressenter
Double-click on the required transaction in the tree structure
Position the cursor on the required transaction in the tree structure and selectEdit Execute (or press F2)
Expand the command field and enter the transaction code
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Standard Toolbar
The Standard Toolbar contains the Command field and the
standard SAP Toolbar buttons.
Command Field: The Command field is used to enter transaction
codes that take you directly to a system task without using
menus.
Button
Keyboard Shortcut
Description
Button
Keyboard Shortcut
Description
Enter Key
Enter/Continue
Ctrl + Page Up
First page
Ctrl + S Save to database Page Up Previous page
F3
Back
Page Down
Next page
Shift + F3
Exit System Task
Ctrl + Page Down
Last page
F12
Cancel
None
Create New session
Ctrl + P
None
Create shortcut on Desktop
Ctrl + F
Find
F1
F1 Help
Ctrl + G Find next Alt + F12 Customize Local Layout
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SAP Easy Access Settings
Users can set how SAP displays the Menu by choosing Extras Settings. Here,
you can specify whether:
Your favorites should appear before or after the menu
Only your favorites, and not the menu, should appear
The SAP Easy Access graphic should appear on the right-hand side of the
screen.
Technical names of menu options should appear in the navigation area
U S tti
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User Settings
Users can maintain their own settings by choosing System User Profile Own
Data
Defaults
Change default printer, language, and date and decimal display formats.
Parameters
Allow user to create default information for frequently used fields.
M
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Messages appear either in the status bar or in a pop-up window, depending onuser settings
Messages starting with:
“E” indicate an Error message
“W” indicate a Warning message
Messages not beginning with an “E” or a “W„‟ are simply Informationmessages
Required fields are denoted by a check mark
Messages
U i O li H l
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Using Online Help
Field Level Help
Used to describe what acurrently selected field isdesigned to do.
Click on the Help icon or „F1‟.
Example:
Find definition of Material number
Click Material field
Click Help button or press F1
key
Click Cancel button to returnto the screen
SAP M il
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• SAP Mail system is used to send a mail to other users of SAP in.
• The recipient is identified by User ID of SAP e.g., STR_PM3, STR-PM1,.,
• SAP Mail can be used for sending information regarding a Notification,
order, equipment etc., through SAP screen or
• through the SAP menu by tcode SBWP (Sap Business work place) for a
normal message.
Procedure :
• In a SAP screen Go to
“services for object” .
• In the following screen click on
„Send‟ icon.
SAP Mail
SAP M il
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• Enter message
• If the mail is required to
be attended immediatelycheck „Express mail‟
• Enter recepient
• Click „Send‟
• or use tcode „sbwp‟ and
follow as detailed below
SAP Mail
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Plant Maintenance
Overview
Section
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PM-01 Organization Structure
PM-01-01 – Organization Structure
Section
Organization Structure
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Organization Structure
Maintenance Planning Plant
Maintenance Plant
Aeration
BioSludge
Air Comp
System
H2SO4
Transfer
Boiler
Blowers
Functional
Locations
Organization Structuring – 1/5
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Organization Structuring – 1/5
A grouping of legal,
organizational, business
and/or administrative
units with a commonpurpose. Single database
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Organisation Structuring – 2/5
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Organisation Structuring – 2/5
Represents an independent
accounting unit within a
client. Each company code
has its own balance sheetand its own profit and loss
statement.
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance PlanningPlant
Organisation Structuring – 3/5
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Organisation Structuring 3/5
Operational unit withina company code.
•Material Valuation
•Inventory Management•Material Master
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance PlanningPlant
Organisation Structuring – 4/5
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Organisation Structuring – 4/5
• Maintenance Objects
• Work Centres
• Same as Plant
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance Planning
Plant
Organisation Structuring – 5/5
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Organisation Structuring – 5/5
Planner Groups
• Task lists
• Maintenance Plans• Order Creation
• Resource Planning
• Work Scheduling
Company Code (s)
Plant (s)
Client
Maintenance Plant
Maintenance PlanningPlant
Definition of the Organization Elements
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Definition of the Organization Elements
Company Code: The smallest organizational unit for which a complete
self-contained set of accounts can be drawn up for purposes of external
reporting.
Maintenance Plant: Plant, in which the technical objects of a company
are installed.
The planning responsibility for a maintenance plant is defined by using
a planning plant. Maintenance plants are assigned to maintenance
planning plants.
Maintenance Planning Plant: Plant in which maintenance tasks are
planned and prepared.These tasks can relate to technical objects in
your own plant or in other plants.Maintenance planning plants are
normal plants that are indicated as maintenance planning plants in
Customizing. Maintenance plants, which do not plan their own
maintenance tasks, are assigned to the planning plants. Planning is
performed for the maintenance plants in the planning plants entered.
Section
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PM-02 Master Data
PM-02-01 – Functional Location
PM Functional Location
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A functional location is an element in a technical structure, representing an
area/spatial/functional of a Plant at which
Equipment/s can be installed.
Structure Indicator
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Edit Mask – xxx-xxx-xxx-xxxx-xxx-xxxxx
Hierarchy levels 1 2 3 4 5 6
LEVEL 1
LEVEL 2
LEVEL 3
LEVEL 4
LEVEL5
LEVEL6
LEVEL 7
Functional Locations-Criteria
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Criteria for Functional Location :
Execution of Maintenance Tasks
Recording of Maintenance Task
Data Collection over long periods of time
Cost Monitoring by Area
What affect do the Usage Condition have on thelikelihood of Damage to the installed aggregates.
Used normally for the object which are not movable.
Understanding the Transaction
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g
PM-03-02-01 Master Data – Functional Location
Functional Location Structure using Tcode IH01
List Display of Functional location using Tcode IH06
Section
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PM-02 Master Data
PM-02-02 – Equipment
Equipment-Criteria
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Criteria of Equipments :
Management of Individual Data
Recording of Maintenance tasks
Object based recording of costs
Evaluation of technical data
Recording of Usage Times
Equipment Usage List
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Understanding the Transaction
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PM-03-02-02 Master Data – Equipments
Equipment Structure using Tcode IH03
Section
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PM-02 Master Data
PM-02-03 – Measuring Points
Measuring Points
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Measuring points in the R/3 System describe the physical and/or logical
locations at which a condition is described, (for example, the compressor
discharge pressure).
Measuring points are located on technical objects ie. on pieces of
equipment or functional locations.
Measuring Point can be either a parameter value or a counter.
Measurement Readings are entered for the measurement point with
reference to a specific time.
Notifications can be generated automatically if the value of the measuring
reading exceeds the range specified in measuring point.
Measurement and counter readings are stored in the system in the form
of measurement documents. These documents are the basis for
performance-based maintenance planning
Understanding the Transaction
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PM-03-02-03 Measuring Points
Display Measuring Point using Tcode IK03
Create Measurement Document using Tcode IK11
Section
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PM-02 Master Data
PM2-02-04 – Bill of Material(BOM)
Bill of material
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Bill of Materials BOMs)
– A complete, formally structured list of the components making up a technical object
–The list contains the individual components together with their quantity and unit of measure
–The components can be stock or non-stock spares or assemblies
Purpose
–Material/spare parts planning
•to assign materials/spare parts to a maintenance order.
–Locating malfunctions
•to locate the malfunction in the piece of equipment or in its bill of material for a
maintenance notification.
–Material assignment
•to assign material to the individual operations of a task list.
Bill of material –
for equipment
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10
Equipment - 10006767
Centrifugal Pump”
Equipment BOM
Casing type A 100-100 1 PC
PC
PC
PC
PC
PC
PC
PC
PC
30
40
50
60
70
80
90
20
Shaft
Sleeve
Bearing - A
Bearing - B
Wear Ring A
Wear Ring B
Impeller
Seal 100-300
100-400
100-500
100-600
100-700
100-800
100-900
100-200
1
1
2
1
1
4
1
2
Understanding the Transaction
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PM-03-02-04 BOM
Display Equipment BOM using Tcode IB03
Display Functional Location BOM using Tcode IB13
Section
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PM-02 Master Data
PM-02-05 – General task List
Plant Maintenance task list –
Check list
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THESE TASKS ARE , FOR EXAMPLE :-
• INSPECTIONS - Determining the actual condition.
• MAINTENANCE - Maintaining the ideal condition.
• REPAIRS - Restoring the ideal condition.
SEQUENCE OF INDIVIDUAL MAINTENANCE TASKS
WHICH REPEATEDLY HAVE TO BE PERFORMED ON A
MACHINE OR AT A SPECIFIC AREA.
Task List
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Maintenance task lists describe a sequence of individual maintenance activities
which must be performed repeatedly within a company. The functions for
creating data in equipment task lists, functional location task lists and general
maintenance task lists are very similar and will therefore be dealt with jointly in
this section.
1. You create operations and, where necessary, sub-operations and enter detail
data for internal or external processing.
2. You can include user data in the operations or sub-operations, as required.
3.
You can assign the following objects to the operations:
Material components
Production resources/tools
Maintenance packages
Inspection characteristics You can arrange the operations according to time by
defining relationships.
You can perform a cost analysis.
Task list categories
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Equipm ent 2
Equipment
Funct ional locat ion
TL
Taskl ist
categories
FL1
Op. 1
Op. 2
Op. 3
FL2
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
TL TL
Equipm ent 1
TL
General task l ists
Pumps
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
Cleaning
Op. 1
Op. 2
Op. 3
Op. 1
Op. 2
Op. 3
Task List Group Counter
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Understanding the Transaction
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PM-03-02-05 Task List
Display Equipment Task List using Tcode IA03
Cost Maintenance Task Lists using Tcode IA16Material Where used list: Task List using Tcode IP62
Section
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PM-02 Master Data
PM-02-06 – Maintenance Plan
Types of Preventive Maintenance
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2001
Performance-basedTime-based
PreventiveMaintenance
Maintenance Plans
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Maintenance plan
Single cycle plan Strategy plan Multiple counter plan
Time-based Performance-based
Maintenance Plans
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Maintenance Plan Functions
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Scheduling Period
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Scheduling data
Maintenance item
Maintenance plan
Order 901760
Cycle start Scheduling period
Schedule in future
displayed for the
specified scheduling
period
Planned dates
Orders
Scheduling period
1 year
Call Horizon
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Maintenance item
Maintenance plan
Order 901760
Scheduling data
Cycle
start
Call date derived from
the call horizon Planned date
Cycle 3 months = 90 daysCall horizon at 90% = 81 days
Shift Factor
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Maintenance item
Maintenance plan
Scheduling data
Cycle start
Technical completion
30/07/2003
Planned dateCycle 1 month
Shift factor 100%
Planned date
New planned date
30/07/2003(shifted by100%)
Tolerances can be used in combination with Shift factors to control theshifting of future planned dates
Cycle Modification Factor
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Maintenance item
Maintenance plan
Scheduling data
Cycle start
Cycle modification
Factor
1.5
Planned date New planned date
Cycle
3 months 4.5 months
Scheduling Indicator
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Scheduling Indicator
Scheduling data
Maintenance item
Maintenance plan
“Time” 1 month = 30 days
Time
Time-
key date
Time-
Factory cal.
Scheduling
indicator
“Time key date” Falls due on exactly the
same date as per the cycle
“Time Factory calendar” Falls due as per the cycle with
factory calendar as the
reference for calculating time
Cycle start
Cycle start
Cycle start
Deadline Monitoring
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= Planned dates
Orders for the
next 90 days
Order
Deadline monitoring
Date of deadlinemonitoring run
Order 901760
Cycle 1 month
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Maintenance Strategy
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Package definition3 months
6 months
Maintenance Strategy
Scheduling indicatorTime
Time – using key date
Time using Fact. calendar
Strategy unitShift factors
Tolerances
Factory calendar
Scheduling Parameters
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Understanding the Transaction
PM 03 02 06 Maintenance Plan
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PM-03-02-06 Maintenance Plan
Display Maintenance Plan using Tcode IP03
Schedule Maintenance Plan using Tcode IP10Scheduling of Maintenance Plan using Tcode ZPMIP30
Maintenance Plan Cost Display using Tcode IP31
Maintenance Cycle Set using Tcode IP11Z
Add Multiple Counter Plan using Tcode IP43Maintain Maintenance Strategies using Tcode IP11
Add Strategy control Plan using Tcode IP42
Section
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PM-02 Master Data
PM-02-07 – Catalogs
CATALOGS
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CATALOG PROFILES
CATALOG TYPES AND
CATALOG CODE GROUPS
CODES AND DESCRIPTIONS
In PM, only the catalogs type 2,5,A,B,C is used.
Catalogs
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CATALOG TYPE (B)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -1/5
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CATALOG TYPE-(B)
(OBJECT PARTS)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -2/5
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CATALOG CODE (2)
(TASKS)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -3/5
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CATALOG CODE (C )
(DAMAGES)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -4/5
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CATALOG CODE (5)
(CAUSES)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -5/5
CATALOG CODE (A)
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CATALOG CODE (A)
(ACTIVITIES)
Understanding the Transaction
PM-03-02-07 Catalogs
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Maintain Catalog using Tcode QS41
Section
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PM-02 Master Data
PM-02-08 – Work Center
Work Centers in PM
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Work center : An Organizational unit
It defines where and by whom an operation is to be performed.
Work Center in PM Module will be :
Group of Persons for eg. Multi Disciplinary team / Electrical /Mechanical / Instrumentation Team.
The work center is specified in master data of equipment or
functional location, maintenance item, task list header,
operations of task list, order header and order operations.
Work Center Contents
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Work Center : Main Functions
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Understanding the Transaction
PM-03-02-08 Work Center
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Display Work Center using Tcode IR03
Section
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PM-02 Master Data
PM-02-09 – Warranties
Warranties
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Warranties define the scope of the services that a Vendor
should provide for a technical object in the event of damage orproblems for the validity period.
Warranties to pieces of equipment of functional locations.
Warranty in PM is :
Vendor Warrantee (for example, manufacturer or vendorwarranty)
Structure of Warranty
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Warranty
header
Warranty type
Description
Classification
Warranty
items
Service activities
inclusive/exclusive
Warranty
counter Counters , limits
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PM-02 Master Data
PM-02-10 – Classification and Permits
Classification
Classification system uses characteristics & values to describe all
t i t d t i il i t i l
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types equipment, and to group similar equipment in classes.
Classification helps in finding equipment more easily, using thecharacteristics defined in them and values as search criteria.
This also helps in finding equipment with similar or identical
characteristics.
Classification
Type Centr if ugal / Screw /Reciprocating
Capacity 50 m3/hr / 75 m3/hr / 100 m3/hr
Character istics and Values
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Capacity 50 m3/hr / 75 m3/hr / 100 m3/hrRPM 975 / 1450 / 2900Head 10 M t / 20 M ts / 30 M ts
Stages 1 / 2 / 3F lu id Oil / Water / Acids
Class PUMP – Type – Capacity – RPM – Head
– Stages – Fluid
Assignment of a pump toclass pumpAssigned valuesType - Centr if ugalCapacity - 75 m3RPM - 1450Head - 10 mtStages - 1F lu id - Water
F ind a pump in Class PUMP with capacity = 75m3
Class
Maintenance Classification
Locating a pump
Permits (Technical Permits) / Process Permits
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Understanding the Transaction
PM-03-02-10 Classification and Permits
Characteristics using Tcode CT04
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Characteristics using Tcode CT04
Classes using Tcode CL02
Find objects in classes using Tcode CL30N
Maintain Permit using Tcode IPMD
Let us Get into Hands-on right now
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Now, let us startunderstanding what we
discussed, better with
Hands-on Practice using
the Exercise Sheet PM-02-10.
Section
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PM-03 General
Maintenance ProcessingPM-03-01 – Notification Processing
PM Notification Structure
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Object Information
The Object Information contains
Structural Data, Classification
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Structural Data, Classification
Data, Previous Damage, number
of days to solve the problem,Previous notification
created/completed for the
technical object, maintenance
plans and documents for the
object.
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Understanding the Transaction
PM-03-03-01 Notification Processing Create PM Notification using Tcode IW21
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Create PM Notification using Tcode IW21
Create PM Malfunction Report using Tcode IW24
Section
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PM-03 General Maintenance
ProcessingPM-03-02 – Order Processing
Plant PM Planning PM Work Center
3P bl E
Damage Related Process Maintenance Flow
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Technical Info.
•Breakdown
•Causes,Activities
•Object affected
PM Notification
•What
•When•Where
•Technical
Information
•Breakdown
Completion
PM History
PM Order
CompletionConfirmation
1
3
4 5
Completion
6
8
2
Problem , Error
Malfunction,Request,ActivityExecution
•Material
Withdrawals
•Utilities
•Work steps
Requesting
a Task
PM Order creationExecution plang.
•Who
•When, How long
•What work steps
•Account Assign.
•Resources
Task Planning.
7
Maintenance Processing
Notification creationPR creation
PR release as per BDP
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Orderrequired ?
Order Creation
Order ExecutionMaterial withdrawal Work
Clearance/permits
Technical Completion
Order Settlement Notification Completion
Yes
No
Update technical history
Tendering, PO
creation, GR atstores and
transportation to
local storage as
per MM, OLM
procedure
PR release as per BDP
Business Completion
Maintenance Activity Types In Orders
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Maintenance Order Processing
Elements of Maintenance Order
Order headerFor example: Order Type, Dates,Plant, Main object,
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Order headerPriority, Description, Maintenance Activity type
Object listFor example:- Functional Locations, Equipment
Maintenance Notifications, Assemblies.
OperationFor example: Work Center, Control key, Descriptions
Standard time, Activity type,
Material list For example: Material, Quantity, Storage Location
Production resources/tools
Settlement Rule
Costs
(Estimated / Planned / Actual)
Operations
Operations
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Operation Work Center Control key Description Activity Type
0010
0020
0030
0040
0050
MECH
MECH
MECH
MECH
ELEC
PM01
PM01
PM01
PM01
PM01
Oil change
Drain oil
Change oil filter
Add new oil
Check cable
List of operations
MAINT
MAINT
Stock Material Process Flow
Component
assignment
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May
assignment
Material
Reservation
Order
Release
Printing
Goods
issue
May
Automatic
availability
check
Availability
check
Order Release
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Reservation effective,
can be withdrawn
Shop Papers can be printed
Confirmation possible
Goods movement possible
Effects of Order Release:
Order Debits after Settlement
Other PostingsOrder Execution
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Act. Costs > 0Act. Costs > 0
• Invoice receipts
• Controlling
Postings,
• Completion
Confirmations
• Material
Withdrawals
Maintenance
Order
Order Settlement
After settlement actual
Cost on the Order is“ZERO”
Order Processing Summary
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ControllingPlant Maintenance
Order
• Order not Modifiable
• Postings can be
made to the Order
• Postings cannot
be
Made to Order
P l a n n i n g
R e l e a s e
E x e c u t i o
n
C o m p l e t i o n
C o n f i r m
a t i o n
T e c h n i c a l
C o m p l e t i o n
S e t t l e m e n t
( B u s i n e s s )
C o m p l e t i o n
Time
PM Order Costing
PM Order Costs
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Internal activityOp. 10:- 3 hrs
Op. 20:- 1 hr
External processing
Op. 30:- EXTERN 1 hr .
Warehouse issue
2 pcs Material ABC
Rs. 500
Rs. 150
Rs. 300
Internal processing:-
External Services:-
Warehouse Issue:-
Total:- Rs. 950
COST CENTER
PM Order settlement
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Sett lement: - Fixed Amoun t OR percentage Distr ibut ion
Equipment 4011
Operation 010: 10h
Workcenter Mech
Operation 020: 3h
Workcenter Electrical
PM Order
WorkCenter'Mech'
Work Center
Electrical
Material Receiver
Activities :-
Mech. activity.
Elect. activity.
COSTCENTRE
COST CENTER(MAINT)
Maintenance Processing Cycle
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Action Logs
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Order Hierarchy
If maintenance order consists of several independent steps whose
costs should be separated, order hierarchy can be used.
All b d h ld b l t d b f i d b
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All sub-orders should be completed before a main order can be
completed.
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Understanding the Transaction
PM-03-03-02 Order Processing Create PM Create Order Processing Tcode IW31(Normal)
C t PM C t O d P i T d IW31(R f bi h t)
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Create PM Create Order Processing Tcode IW31(Refurbishment)
Create PM Create PM Sub Order using Tcode IW36
Goods Withdrawal using Tcode MB1A
Completion Confirmation using Tcode Tcode IW41
Overall Completion Confirmation using Tcode IW42
Section
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PM-04 Refurbishment CyclePM-04-01 – Refurbishment Cycle
Refurbishment Processing
Types of Refurbishment
Refurbishment Order
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Refurbishment Order
OEM Repairs Central Workshop
Refurbishment cycle - OEM
Create N9
N tifi ti
CreatePM60 type of
M i t O d
Uninstall
Equipment .
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Notification Maintenance Order
Create PR/PO
q p
install at Vendors FL
Create Batch and
And send to stores with
movement type 202
Refurbishment Cycle .. contd
Send Equipment
To vendor
movement type 541
Receive Equipment (GR)
Send equipment
To Function location
Movement type 261
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movement type 541
Settle & Close Order
Movement type 261
Complete Order
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Refurbishment Cycle .. contd
Create Refurbishment
OrderReplace defective parts
Complete the order.
Settle to Asset
Cost Center
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To Asset
Cost Ce te
Transfer Posting from
Workshop to Asset
Refurbishment Cycle .. contd
Send Equipment
From stores to F.
Movement type 201
Install Equipment
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yp
Create
Notification
‘N9’
IH01or IW21
Maintenance
order for
repair ‘PM60’
IW31
Create a
BATCH
MSC1N
Transferring
to Stores
MB1A (202)
Refurbishment cycle for repair at OEM/External
Dismantle
equipment &
install at Repair
Location
IE02
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CreatePurchase
Requisition
ME51N
Create &
release
Service entrysheet
ML81N
Change Equipment
data & Install at
original locationIE02
Stores to
Functional
locationMB1A (201)
Vendor to
Company after
repairMB1B (542)
Send to
vendor
MB1B(541)
ReleasePurchase
Requisition
ME54
Release
Purchase order
ME28
Transaction codeXXX
Create Purchase
Order
ME21N
Maintenance
order
CompletionIW32 / MIGO /
IW41 / TECO
Complete
Notification
IW22
323
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Section
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PM-05 Work Clearance
ManagementPM-05-01 – WCM
WCM
Reasons for Work Clearance Management : -
Maintenance Crews require safety measures.
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q y
Maintenance activity need to be performed while the systems are
operational
Work related measure which require special health and safety measure
ie. Controlling and monitoring lockout and tagout of various
equipments.
WCM and Maintenance Process
WCM
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WCM Architecture
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The work clearance application represents the safety certificate especially forlockout/tagout.
In Plant, we will use WCA for getting prior approval to carry out any maintenance job that requires WCM.
Two types of WCA :
Hot job/Cold Job - Do not require WCD
Tagout - Requires WCD
The work clearance document describes lockout/tagout. It contains a list of the
technical objects in a technical system to be tagged or monitored. It controls thephysical blocking and signposting of the technical objects affected. It alsocontains a detailed description of how the system should be isolated.
WCM Architecture
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WCM Model
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WCM Permit
WCM type permit to be attached to the order for initiating WCM
WCA contains approvals to be granted for job execution
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WCD contains approvals to be granted to ensure safe workingconditions.
Phases and Roles
Phases / Roles
Order Create Order Order Creator
WCM Objects Phase/Proces
s
Carried out by
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Work Clearance
Appl icat ion
Work Clearance
Appl icat ion
Work Clearance
Document
Approve / Perform
Tagout
Various concerened
agencies like control
room, electrical,
mechanical, safety
Competent AuthorityApprove Work
Specify Objects
Containing TagoutOrder Creator
Application for
executing the
above orderOrder Creator
Work Clearance
Document
WCM Process
1. A Maintenance Executives (maintenance in-charge, sectional heads) creates a
maintenance Order
2. If the job requires work clearance Maintenance Executives creates the WCA for
the order and requests the approval from competent authority to perform the job.
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3. He also creates / copies from a template a Work Clearance Document. The WCD
contains details the tagging/un-tagging conditions of all the equipment / functional
locations / any other object (even w/o master data) which need to be tagged to
carry out the above maintenance work.
4. WCA created above is approved by the competent authority giving the clearance
for executing the maintenance activity.
5. At the time of actual execution, the tag out / lockout of the equipment mentioned
in the WCD is approved by various concerned agencies like control room,
electrical, mechanical, safety and their status is maintained in the system.
6. Any conflict in the status of any of the specified equipment / functional location
is prompted by the system.
WCM Process
Phases / Roles
Order (after
tagging)Labour Release
Maintenance In-
charge / Executor
WCM Objects Phase/Proces
s
Carried out by
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Order
Work Clearance
Document
Work Clearance
Appl icat ion
Technical complete
the orderMaintenance Incharge
Perform Un-
Tagging
Closed Approving authority
Confirm that work
in the order is
comp
Maintenance
Executive
Order
WCM Process
6. When Tagging has been performed, the maintenance In charge can release the
order ( Labor release). Order release can take place independently of this.
7. After the work has been carried out and tag-out/log-out is no longer required, the
maintenance executive sets the status Work complete for the order. Technical
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completion is possible only on WCD completion.
WCA Status Sequence
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WCD Structure
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WCD
Enter all technical objects that are to be processed using tag-out /
logout. The WCD may include equipment, functional locations and
items not maintained in the R3 system.
Th WCD t i th d t il d d i ti f h th t h ld
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The WCD contains the detailed description of how the system shouldbe isolated.
The WCD controls the physical isolation and placing of tags on
affected technical objects (items).
WCD
The WCD template is used as a copy model when creating work
clearance documents.The work clearance document template itself
cannot be used to perform lockout/tag-out. Therefore, it cannot be
tagged/untagged or assigned. With template, the work clearance
d t f l t t f t h i l t d t
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documents for complex structures of technical systems do notalways have to be recreated.
The operational cycle is divided into the following operational
phases:
Tagging
Temporary un-tagging
Un-tagging
In the operational cycle, the items in an operational work clearance
document run through several statuses for each operational phase in
a specific sequence.
WCD Items
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Operational Cycle
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Operation Group
The WCD items defines the technical objects which need isolation for
lockout/tagout.
Operation condition gives the detailed description of conditions /
parameters for technical object (open /closed)
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parameters for technical object (open /closed)
Each operation condition is valid for tagging / untagging.
Operational group is a logical grouping of operation conditions
designed to minimize the conflict.
For a technical object to be tagged / untagged, the system checks if
this objects is already a reference object in a processed Operational
WCD. A technical object cannot have different operational
conditions.
Operation Protection/Conflict Management
Protection which ensures that a technical object, which is managed as an item in an
operational work clearance document, can only be tagged/untagged from certain
Operation WCDs.
The operational protection can be used to protect the un-tagging of a position of
the operational work clearance document against other operational work clearance
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the operational work clearance document against other operational work clearancedocuments.
The operational protection can be used to create protected areas. A protected area
is defined using the following criteria:
Operational protection of items in operational work clearance documents that
represent technical objects
Direct linking of operational work clearance documents using superior work
clearance applications
A technical object with operational protection can be tagged/untagged within the
protected area. However, it is not possible to tag/un-tag the technical object
outside of the protected area.
Section
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PM-06 Calibration CyclePM-06-01 – Calibration Cycle
Calibration Processing Cycle
Create Measurin g Po int
Calibration
plan
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Classi f icat ion
Assign to Measur ing Point List
Ass ign Measur ing
Lis t
to task List
Calibration Order
Enter Readings
Calibration Cycle
Create Measuring point of Category ‘C’ for each calibration value.
Ass ign Measurement p osi t ion fo r cal ibrat ion value.
Ass ign Measur ing Point to Task l ist .
C t i t l t t l ib t i i t d t k l i t
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Create maintenance plan w rt to cal ibrat ion equipment and task l ist .
Schedu le the maintenanc e plan and release order
Enter the measurement reading fo r the equipment
Eg for a Dif f pressure f low meter with p ressure and temperatureco rrect ion s and c al ibrat ion c heck for 0,25,50,75 and 100% values, 5measur ing points for each parameter ie. total ly 15 measur ing pointexists for the meter.
Understanding the Transaction
PM-03-06-Calibration cycle Create measuring point IK01.
Create Measuring reading t entry list IK31.
Create Equipment task list IA01
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Create Equipment task list IA01
Create measuring plan IP41
Release Order IW32.
Enter measuring reading IK34
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PM-07 PMISPM-07-01 – PMIS
Reporting and AnalysisMaintenance Process
PM Information system
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Noti-fication
WorkOrder
Objects Downtime
CostsMTBR
Info Database
Apply
Noti-fication
Equip-ment
Info DatabaseHisto
ry
Graphic
ABC analysis
Classification
TOOLBOX
Plant Maintenance Reports
Analysis o f Maintenance Order Costs as per internal labor , material, services cost.
Monitor ing o f Maintenance ord er compl iance / back log s forPlanned / unplanned / emergency o rder.
Break down analysis as per cause damage and part fai lure
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Break down analysis as per cause , damage and part fai lure.
Manufacturer w ise analysis of Equ ipment maintenance.
Mater ial Cons umption report for Equipment.
Mean time to repair and mean time between fai lure reports fo rEquipments.
Cal ibrat ion test reports for Instrum ents.
Measuring value parameters for equipment
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Thank You
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