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End User Manual

                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




  Project Sarthak




                                  Table of Content.
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End User Manual

                                 Title: SAP PM
                                   Module:                   PLANT MAINTENANCE
                                   Release:                  ECC 6.0
                                   Created by:               RAVINDER KUMAR
                                   Created on:               23 Nov‟10




S.No.                                                                                                                               Page No.

1.          Introduction ............................................................................................................ 4
2.          Getting Started ....................................................................................................... 6
3.          Master Data .......................................................................................................... 18
     3.1        Functional Location ................................................................................................................... 18
     3.2        Equipment .................................................................................................................................. 29
     3.3        Equipment Bill of Material ........................................................................................................ 43
     3.4        General maintenance Task lists .................................................................................................. 50
     3.5        Work Permit ............................................................................................................................... 59
     3.6        Characteristic ............................................................................................................................. 67
     3.7        Measuring Points ....................................................................................................................... 71
     3.8        Work Center ............................................................................................................................... 80
     3.9        Maintenance Planning ................................................................................................................ 85
     3.10       Maintenance Plan Scheduling .................................................................................................... 92
4.          Maintenance Processing .................................................................................... 102
     4.1        Measuring documents .............................................................................................................. 102
     4.2        Breakdown Maintenance Process: ........................................................................................... 123
     4.3        Preventive Maintenance ........................................................................................................... 160
     4.4        Regular Maintenance : ............................................................................................................. 203
     4.5        Calibration Process: ................................................................................................................. 209
5.          Plant Maintenance Information System .......................................................... 217
     5.1        Standard Reports ...................................................................................................................... 217




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End User Manual

                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




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End User Manual

                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




1. Introduction

SAP R/3 is an “integrated and industry-independent standard software” which
covers integrates and connects all functional areas in a business. SAP AG defines
integration as "defined communication". Although R/3 is designed for complete
integration, it can also be used for a couple of business areas.


SAP is the abbreviation for “Systems Applications and Products in Data
Processing”.




The purpose of this document is to provide an overview of SAP PM Functionality and
the details of how the transactions are carried out in SAP R/3.


The document has been organized as follows;


 Master data maintenance required for PM module is covered first. Master data
    maintenance is the most important aspect as these data affects all the transaction
    where that Master data is used. It is very much controlled by authorizations as per
    the policy of the company.
 As a PM user, you will be using various transactions to replicate day-to-day work
    in SAP R/3. So all the transactions, which are relevant to you for carrying out
    Plant Maintenance activities, are covered in this.




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End User Manual

                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




Master data maintenance and transaction processes are explained with the help of
SAP screen Shots. This will help you in executing the same perfectly.




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End User Manual

                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




2. Getting Started

    LOG ON:


    Select SAP Log in Icon




    On PC Desktop & press enter key or double click,


    Or follow the menu path as shown in following screen:




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End User Manual

                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




    The following screen will appear.




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End User Manual

                       Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




    Select Server and click on Log on icon


         Logging onto the SAP R/3 system


                  Sap R/3 systems are client systems. The client enables you to run
                   several business operations at the same time in one SAP R/3 system.
                  Client is, in organizational terms, an independent unit in the system.
                   Clients have their own data environment and therefore their own user
                   master and transaction data, assigned user master records and chart
                   off accounts and specific customizing parameters.
                  So that you log on to SAP R/3 system, you must have a master record
                   created for you for corresponding client. For reasons of access

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End User Manual

                       Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




                   protection, you must enter a password when you log onto the sap
                   system. The system does not display the password you enter.
                  SAP R/3 system is available in several languages. Use the language
                   input field to select the logon language for each session.




Elements of the screen layout


                  Command Field: Use command field (hidden as default) to go to
                   applications directly by entering the transaction code.
                  Standard Tool Bar: the push buttons in the standard tool bar are found
                   on every screen in an SAP R/3 system. Any push buttons that cannot
                   be used in a particular application are grayed out. If you place your

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End User Manual

                       Title: SAP PM
                           Module:         PLANT MAINTENANCE
                           Release:        ECC 6.0
                           Created by:     RAVINDER KUMAR
                           Created on:     23 Nov‟10




                   cursor on a push button for a while the system displays a quick info text
                   that explains the push button function.
                  The Application Tool bar: shows which functions are available in the
                   current application.
                  A Tab page: provides a clearer overview of several information screens
                  Status bar: the status bar displays information on the current system
                   status, for example. Warning or error messages
                  Menu bar: the menus shown here depend on which application you are
                   working in.
                  Title bar: the title bar displays the functions that are available for the
                   user.
                  Checkboxes: checkboxes enable you to select several options
                   simultaneously within a group.
                  Radio Buttons: allow you to choose exactly one item form a selection.




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End User Manual

                       Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




The below shown screen gives you a detail explanation.

                                                   Menu
                                                   bar                       Standard
                                                                             toolbar
                                                       Title bar
                   Command
                                                                                Application
                                                                                toolbar

                                      Tab Page




                                                                    Input Fields
                                                                    Check
                                                                    boxes,
                                                                    Radio
                                                                    Buttons




                                                                         Status
                                                                         bar




SAP Easy Access


                  Sap easy access is the standard entry screen displayed after the logon.
                   You navigate through the system using the tree structure.




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End User Manual

                       Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




                                      You are greeted by your
                                      logo in the right-hand
                                      part of the window




         Selecting Functions
                  You can call functions in the system as follows
                      o Menu Option
                      o Favourites
                      o Entry in the SAP easy Access menu
                  “/n” ends the current session
                  “/i” delets the current session
                  “/oCV01N” opens a new session and branches out to the transaction
                   specified (CV01N)



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End User Manual

                       Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




                  By entering “ search_sap_menu” in the command field, you can
                   display menu paths for the desired SAP transaction.




   Command Field




                                              Menu

 SAP easy Access and Favorite
 List



Field help : F1 and F4


                  Use F1 to display an explanation of fields, menus, functions and
                   messages.
                  F1 Help also provides technical information on the relevant field.




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End User Manual

                       Title: SAP PM
                        Module:            PLANT MAINTENANCE
                        Release:           ECC 6.0
                        Created by:        RAVINDER KUMAR
                        Created on:        23 Nov‟10




                                                 F1 Help




                  Use F4 to display possible inputs . you can also access F4 help for a
                   selected field using the button immediately to the right of that field.




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End User Manual

                       Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




                             F4 help




User – Specific Personalization


                  The end user has many possibilities for personalizing the system. For
                   example as shown in the screen below.




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End User Manual

                      Title: SAP PM
                       Module:           PLANT MAINTENANCE
                       Release:          ECC 6.0
                       Created by:       RAVINDER KUMAR
                       Created on:       23 Nov‟10




SAP – Symbols or icons


           Keyboard                                        Keyboard
Button                     Description            Button                      Description
           Shortcut                                        Shortcut

                                                           Ctrl     +    Page First page
           Enter Key       Enter/Continue
                                                           Up

                           Save              to
           Ctrl + S                                        Page Up            Previous page
                           database


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End User Manual

                      Title: SAP PM
                        Module:          PLANT MAINTENANCE
                        Release:         ECC 6.0
                        Created by:      RAVINDER KUMAR
                        Created on:      23 Nov‟10




                                                                             Next page
           F3               Back                        Page Down

                            Exit         System         Ctrl     +    Page
           Shift + F3                                                        Last page
                            Task                        Down
                                                                             Create       New
           F12              Cancel                      None                 session


                                                                             Create    shortcut
           Ctrl + P         Print                       None
                                                                             on Desktop
                                                                             F1 Help
           Ctrl + F         Find                        F1

                                                                             Customize Local
           Ctrl + G         Find next                   Alt + F12
                                                                             Layout




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End User Manual

                      Title: SAP PM
                       Module:           PLANT MAINTENANCE
                       Release:          ECC 6.0
                       Created by:       RAVINDER KUMAR
                       Created on:       23 Nov‟10




3. Master Data
3.1 Functional Location
 Functional locations are elements of a technical structure (for example, functional
 units within a system). Functional locations can be created according to the
 hierarchy, and can be structured based on the following criteria:

        Functional

        Process-related

        Spatial


 Each functional location is managed independently in the system, to :

        Manage individual data from a maintenance perspective for the object

        Perform individual maintenance tasks for the object

        Keep a record of the maintenance tasks performed for the object

        Collect and evaluate data over a long period of time for the object



Trigger:
Functional locations need to be structured according to functional, process-related or
spatial criteria. Whenever any new location identified we need to create Functional
location.


                      BUSINESS PROCESS PROCEDURE OVERVIEW
A functional location is an organizational unit to structure the maintenance objects of a
company according to functional, process-related or spatial criteria.

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End User Manual

                    Title: SAP PM
                     Module:             PLANT MAINTENANCE
                     Release:            ECC 6.0
                     Created by:         RAVINDER KUMAR
                     Created on:         23 Nov‟10




                     BUSINESS PROCESS PROCEDURE OVERVIEW
A functional location represents the place at which equipment(s) can be installed and a
maintenance task is to be performed.




Output – Results                                                    Comments
Functional location created



Procedural Steps


       ID: PM                           Title: Maintaining of Master data – functional
                                        location
       Business process:                Functional Location
       Transaction       code: Menu                path:   Logistics     Plant   maintenance
       IL01, IL02                       Management of Technical Objects  functional
                                        location  Create (IL01)




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End User Manual

                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




     Description:
     Use this transaction for creating structured location
     Double CLICK on selected line or press Enter to get following screen




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                     Title: SAP PM
                         Module:        PLANT MAINTENANCE
                         Release:       ECC 6.0
                         Created by:    RAVINDER KUMAR
                         Created on:    23 Nov‟10




     Instructions
     In the initial screen, enter the values in the following fields:


       Field name                 Required User action and allowed values
                                  /
                                  Optional
       Functional location              R     Functional location code is to be entered as per
                                              the structure
       Structure indicator              R     Structure of func. With hierarchy level
       Fuct. loc. cat.                  R     Type of fictional loc.




“Press enter key“ or click on icon


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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




Field name             Required User action and allowed values
                       /
                       Optional
Description                R            Functional Location. Name is to be entered
                                        (40characters). If the name exceeds, use long
                                        text.




Ensure General data screen is open or click on GENERAL TAB




       Field name              Required User action and allowed values
                               /

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                   Title: SAP PM
                       Module:            PLANT MAINTENANCE
                       Release:           ECC 6.0
                       Created by:        RAVINDER KUMAR
                       Created on:        23 Nov‟10




                                  Optional


       Weight                        O          Weight of the Functional Location
       Size                          O          Size of the Functional Location
       Start up date                 O          Actual start date of usage
       Acquisition value             O          Value of the Functional Location at the time of
                                                acquiring
       Acquisition date              O          Date on which the Functional Location was
                                                acquired
       Manufacturer                  O          Manufacturer of the Functional Location
       Manufacturing                 O          Country, where the Functional Location was
       country                                  manufactured
       Model number                  O          Model number of the Functional Location
                                                supplied by the manufacturer
       Constr. Yr/mth                O          Year    and    month     of   Functional   Location
                                                constructed
       Manuf Part No.                O          Part number of the Functional Location as
                                                supplied by the manufacturer
       Manuf Serial No.              O          Serial number of the Functional Location as
                                                supplied by the manufacturer




After entering required data click on LOCATION TAB




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




Field name            Required User action and allowed values
                      /
                      Optional
Maintenance plant         O            Maintenance        plant,       where   the   Functional
                                       Location is located
Location                  O            Location of the Functional Location, for ex:
                                       Building where it is installed.




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




Field name            Required User action and allowed values
                      /
                      Optional
Plant section             O            Further low level identification of location.
Work center               O            Production work center, for blocking from
                                       production during maintenance work.
ABC Indic                 O            As detailed below :




After entering required data click on ORGANISATION TAB




TO GET FOLLOWING SCREEN :




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                    Title: SAP PM
                     Module:            PLANT MAINTENANCE
                     Release:           ECC 6.0
                     Created by:        RAVINDER KUMAR
                     Created on:        23 Nov‟10




Field name              Required User action and allowed values
                        /
                        Optional
Company code                R            R/3 will copy the respective company of the
                                         maintenance plant.
Business area               O            For viewing profit and loss statement/area wise
                                         costing.
Asset                       O            Appropriate asset number should be assigned
                                         to the Functional Location.
Cost center                 O            All the costs incurred at the Functional Location
                                         level are collected at these cost centers level.
Planning Plant              O            Maintenance planning plant, defaulted as that of
                                         maintenance plant.
Planner group               O            Planner    groups      as      per   the   maintenance
                                         planning activities.
Maintenance        work O                Maintenance work center, currently represents
center                                   the departments like ME, EE, IE, CE & SE
Catalog profile             O            For Functional Location history generation all
                                         the codes are maintained in a catalog profile.




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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




After entering required data click on STRUCTURE TAB
You will reach the following screen




       Field name              Required User action and allowed values
                               /
                               Optional
       Functional Location         O         Functional location under which the Functional
                                             Location is functioning.
       Superior Functional O                 Superior Functional Location under which the
       Location                              Functional Location is functioning.
       Tech Ident. no              O         Technical     identification   number   of      the
                                             Functional Location.
       Const Type                  O         Material of construction.




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




Click on                              to Save and following message will be given by
the system




The Functional Location is saved.


Through transaction code IL02, required functional location can be opened for
editing


If Functional location installation is to be changed, click on icon
                                      on structure tab, to get the following screen




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                    Title: SAP PM
                      Module:          PLANT MAINTENANCE
                      Release:         ECC 6.0
                      Created by:      RAVINDER KUMAR
                      Created on:      23 Nov‟10




First dismantle the already existing installation and then input / select new


installation location and click on                    Enter / Continue icon



Click on                                  to    Save the changes made and following
message will be given by the system.


3.2 Equipment
A piece of equipment is an individual object that is to be maintained independently.
Each piece of equipment is managed independently in the system, so that you can:

        Manage individual data from a maintenance perspective for the object

        Perform individual maintenance tasks for the object

        Keep a record of the maintenance tasks performed for the object

        Collect and evaluate data over a long period of time for the object

Pieces of equipment can be installed and dismantled at functional locations. The
usage times for a piece of equipment at a functional location are documented over
the course of time.



Trigger:
Maintenance history needs to be captured for a physical technical object.Whenever
any new Machine/Computer etc. Purchased we need to create Equipment Master.
Correct Equipment Type has to be choosen always for proper functioning.


                     BUSINESS PROCESS PROCEDURE OVERVIEW

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                   Title: SAP PM
                     Module:             PLANT MAINTENANCE
                     Release:            ECC 6.0
                     Created by:         RAVINDER KUMAR
                     Created on:         23 Nov‟10




                     BUSINESS PROCESS PROCEDURE OVERVIEW
This document describes how to create Equipment for use in PM functions. Equipment
are master data to manage physical objects in PM and Customer Service. An
Equipment master data object must be created here before it may be associated with a
Functional Location object.




Output - Results                                                   Comments
Equipment Master created




       ID: PM                           Title: Maintaining of Master data - Equipment
       Transaction       code: Menu             path:   Logistics       Plant   maintenance
       IE01, IE02, IE03,                Management of Technical Objects  Equipment 
                                        Create (IE01)




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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




     Description:
     Use this transaction for creating & maintaining Equipment
     Double click or press Enter Key to reach the following screen




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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




     Instructions
     In the initial screen, enter the values in the following fields:




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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




       Field name              Required User action and allowed values
                               /
                               Optional
       Equipment                             No in put is required as system creates an
                                             internal no,
       Valid on                    R         By default system proposes current date, one
                                             can change to the appropriate valid from date.
       Equipment category R                  Appropriate equipment category to be selected
                                             from the list




       REFERENCE

       Equipment                   O         Already existing equipment can be used to copy
                                             the data
       Material                              Not   applicable           this   is   required   when     a
                                             material/equipment link is required




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                     Title: SAP PM
                      Module:           PLANT MAINTENANCE
                      Release:          ECC 6.0
                      Created by:       RAVINDER KUMAR
                      Created on:       23 Nov‟10




     Press Enter key or click on                Enter / Continue icon to reach the following
screen




     Enter the parameters as detailed below: in „General‟ screen
     Screen fields data entry instruction:
       Field name               Required User action and allowed values
                                /
                                Optional
       Description                  R         Equipment       Name     is   to   be    entered
                                              (40characters). If the name exceeds, use long
                                              text.
       Object type                  O         Type of machine ex: “select from list”




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                    Title: SAP PM
                       Module:            PLANT MAINTENANCE
                       Release:           ECC 6.0
                       Created by:        RAVINDER KUMAR
                       Created on:        23 Nov‟10




       Field name                 Required User action and allowed values
                                  /
                                  Optional




       Weight                         O         Weight of the equipment
       Size                           O         Size of the equipment
       Start up date                  O         Actual start date of usage
       Acquisition value              O         Value of the equipment at the time of acquiring
       Acquisition date               O         Date on which the equipment was acquired
       Manufacturer                   O         Manufacturer of the equipment
       Manufacturing                  O         Country,      where      the   equipment     was
       country                                  manufactured
       Model number                   O         Model number of the equipment supplied by the

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                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




       Field name              Required User action and allowed values
                               /
                               Optional
                                             manufacturer
       Constr. Yr/mth              O         Year and month of equipment constructed
       Manuf Part No.              O         Part number of the equipment as supplied by
                                             the manufacturer
       Manuf Serial No.            O         Serial number of the equipment as supplied by
                                             the manufacturer




Click on                                                   Location Tab to get the following
screen




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       Field name                 Required User action and allowed values
                                  /
                                  Optional
       Maintenance plant              R         Maintenance plant, where the equipment is
                                                located
       Location                       O         Location of the equipment, for ex: Building
                                                where it is installed.


       Plant section                  R         Further low level identification of location.
       Work center                    O         Production work center, for blocking from
                                                production during maintenance work.
       ABCD                           O         As detailed below:


       Indicator           Strategy
               A   Critical
               B   Important
               C   Non-critical




Now Click on                                            Organization tab to get the following
screen




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       Field name               Required User action and allowed values
                                /
                                Optional
       Company code                 R         R/3 will copy the respective company of the
                                              maintenance plant.
       Business area                O         For viewing profit and loss statement/area wise
                                              costing.
       Asset                        O         Appropriate asset number should be assigned
                                              to the equipment.
       Cost center                  R         All the costs incurred at the equipment level are
                                              collected at these cost centers level.
       Planning Plant               O         Maintenance planning plant, defaulted as that of
                                              maintenance plant.


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       Field name                  Required User action and allowed values
                                   /
                                   Optional
       Planner group                    O         Planner       groups       as   per   the   maintenance
                                                  planning activities.
       Maintenance          work O                Maintenance work center, currently represents
       center                                     the departments like ME, EE, IE, CE & SE
       Catalog profile                  O         For equipment history generation all the codes
                                                  are maintained in a catalog profile.




Now Click on                                      Structure tab to get the following screen




         Click here for
         Installation
         at functional
         location




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       Field name              Required User action and allowed values
                               /
                               Optional
       Functional Location         O         Functional location under which the equipment
                                             is functioning.
       Superior Equipment O                  Superior equipment under which the equipment
                                             is functioning.
       Tech Ident. no              O         Technical     identification   number   of      the
                                             equipment.
       Const Type                  O         Material of construction.


The field in the Function location blank, so it is to be selected for the Hierarchy
Icon.




Click on icon                                       on structure tab, to get the following
screen




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First dismantle the already existing installation and then input / select new


installation location and click on                   Enter / Continue icon


If you select the Superior Equipment Instead of Functional Location then that
Equipment will be called SubEquipment.




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                                            WARRANTY
                                            END DATE




                                                   WARRANTY START DATE




Click on                               to   Save the Equipment and following message
will be given by the system




Warranty is the commitment of the manufacturer, vendor, or retailer to guarantee
services to a customer either free-of-charge or only charged in part, over a certain
period of time.


Warranty details of equipment can be incorporated during equipment creation or can
be done in equipment data change transaction and can be viewed through display
mode


Whenever we try to create a notification or order, SAP system will alert with a
warning message with warranty details if the equipment is still under warranty [period
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To accommodate different warranty conditions against different warranty services, a
separate master warranty is to be created and the same is to be assigned to the
equipment master data


       Field name              Required User action and allowed values
                               /
                               Optional
       Master Warranty              O         N.A
       Begin guarantee              O         Start date of warranty
       Warranty end                 O         End date of warranty



3.3 Equipment Bill of Material
A “Bill Of Material” (BOM) is a complete, formally structured list of the components
making up a technical object or an assembly. The list contains the object numbers of
the individual components together with their quantity and unit of measure. The
components can be stock or non-stock spares or assemblies, which in turn can be
described using maintenance BOMs.

BOMs are primarily used for the following purposes:

        Structure description

    BOM describes the structure of a technical object or material. Using maintenance
    BOMs maintenance tasks can be planned

        Assignment of spare parts

    BOM is used in plant maintenance to assign spares for a technical object or
    material. This is shown in the figure below:

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Trigger:
A piece of maintenance equipment requires a bill of material for maintenance
purposes.Whenever any Equipment created we can create its BOM for Structuring.
But Before creating Equipment BOM we need to create Material Master.


                     BUSINESS PROCESS PROCEDURE OVERVIEW
Create a bill of material for a piece of maintenance equipment to describe the
equipment components, maintenance requirements or the assignment of spare parts.




Output - Results                                                      Comments
Equipment BOM created




       ID: PM                           Title: Maintaining of Master data – Equipment
       Business process:                Bill of Material
       Transaction                      Menu     path:     Logistics       Plant   maintenance
       code:IB01, IB02                  Management         of   Technical     Objects   Bill    of
                                        materialEquipment BOMIB01 create




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Description:
     Use this transaction for creating & maintaining Equipment bill of material


Press Enter key or use mouse double click to get following screen




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                               Equipment no




                      Plant

BOM
USAGE




     Press enter key
     In the initial screen, enter the values in the following fields:
       Field name             Required User action and allowed values
                              /
                              Optional
       Equipment                   R         Select Equipment for which BoM     is being
                                             created
       Plant                      R          Enter plant
       BOM usage                  R          Select – 4 for Plant Maintenance




Press Enter Key or Click on                    Enter / Continue icon
To get the following screen


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     Enter the parameters as detailed below : in „Material‟ screen
     Screen fields data entry instruction:
       Field name               Required User action and allowed values
                                /
                                Optional
       Item category                 R         Select Item Category




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       Field name              Required User action and allowed values
                               /
                               Optional




       Component                   R         Select item code




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       Field name               Required User action and allowed values
                                /
                                Optional




       Component                    R         System        defaults     description   of   selected
       description                            component
       Quantity                     R         Enter installed quantity
       Units                        R         System defaults UOM of selected component

Click on                     to save the entered data

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3.4 General maintenance Task lists
Task Lists.
Task list is defined as the set of work instructions that will help a maintenance
planner schedule his day-to-day job in a predefined manner

Maintenance task lists describe a sequence of individual maintenance activities,
which must be performed repeatedly within a company. Task lists are used to
standardize these recurring work sequences and to plan them more effectively.

Task lists can be grouped, for example in to two groups -              "Inspection" and
"Mechanical Repairs".

The individual maintenance task lists within the group "Mechanical Repairs" and are
identified by the task list counter numbers 01 and 02 as shown in following fig.

General Maintenance Task List

         This type of task list is generic in nature i.e. the same general task list can be
used both for       equipment and functional location and also for more than one
equipment or functional location of the same type or different types.

Similar general task lists can be grouped and several individual general maintenance
task lists can be created.

General task lists can be used to reduce the time spent creating individual functional
location/equipment task lists.

Trigger:
Need to prepare a sequence of activities that must be repeatedly performed within a
company.


                     BUSINESS PROCESS PROCEDURE OVERVIEW

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                     BUSINESS PROCESS PROCEDURE OVERVIEW
Maintenance task lists describe a sequence of individual maintenance activities which
must be repeatedly performed within a company. They are used to standardize
repetitive work processes, to plan them more effectively, and to save time when
creating maintenance orders and maintenance plans.



Output – Results                                                    Comments
General Task List created


For General Task Lists
       ID: PM                           Title: Maintaining of Master data - Functional
                                        location
       Business process:                General Task List
       Transaction       code: Menu                   path:              Logistics      Plant
       IA05                             maintenancepreventive            maintenance   Work
                                        schedulingtask listGeneral maintenance Task
                                        lists  Create (IA05)




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Description:
     Use this transaction for creating & maintaining General task list
     Press Enter Key to get the following screen




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       Field name              Required User action and allowed values
                               /
                               Optional
       Group                       R         Enter a group name (8 characters only)
       Profile                     R         PDIL
       Key date                    R         Date from which the task list is to be used




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     Enter the field value according to the following table
       Field name              Required User action and allowed values
                               /
                               Optional
       Group CNTR                  R         System defaults grp cntr is to be entered




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       Work Center              O             Select responsible work center from the list




       Usage                    O             Select 4 for plant maintenance




                                R             Select 4 for plant maintenance
       Status




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     Click on operation tab




     Following screen can be viewed




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     In the initial screen, enter the values in the following fields:


       Field name               Required User action and allowed values
                                /
                                Optional
       Work center              R             Select work center




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       Plant code               R             Define plant code like for Noida Engineering=
                                              1100


       Ctrl key                 R             Pm 01 for internal operations & PM 03 for
                                              external operations
       Operation                O             Describe the operation to be carried out
       description
       Work                     O             System        will    automatically    calculate     by
                                              calculation key
       UN                       O             Unit of measurement for mh
       NO                       O             No of persons required to perform the activity
       Duration                 O             Duration of Operation
       Unit                     O             Unit of measurement for duration
       C                        O             Calculation key –2         ( for calculating duration )


     Repeat the same above operation for required no of activities


     Select components tab for allotting spares required for that activity.




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        Material               O             Select required item code
        Qty                    O             Enter the required qty



Click on                    to save the task list.



3.5 Work Permit
Permits are to ensure that special approval must be obtained before maintenance
orders are executed.



   Permits can be assigned to the following objects:

        Technical objects (functional locations and equipments)

        Maintenance orders



   Different types of work permit are required
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   Permits can be grouped into permit categories, like
        Work permit – General jobs

        Hot work permit - Hot job

        Confined space work permit - permit to work at confined areas

        High reach work permit-Permit to work at elevated places



Trigger:
   A regulation or condition needing to be observed when maintenance work is being
   performed.


                    BUSINESS PROCESS PROCEDURE OVERVIEW
   A permit is a regulation or condition that must be observed when maintenance work
   is to be performed on a technical object. The creation of the permit master record is
   covered in this procedure.
   The permit can be attached to a Functional Location, Equipment master, or directly to
   a work order.
   The requirement can be observed at the release or the completion of a work order.
   The permit can only be for reference, provide a warning, or cause an error message
   unless issued.



Output – Results                                                 Comments
Permit master created                   Master record can be viewed again by selecting row
                                        and choosing details.




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       ID: PM                           Title: Maintaining of Master data – Work Permits
       Business process:                Work permits
       Transaction          code: Menu path: Logistics Management of tech.
       IPMD                             objects Environment  IPMD permits




Select the transaction as shown in the following screen




     Press enter key or double click to reach the following screen

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     To view the next screen press Enter key or click on icon




                                          AND THEN ON




     to view the following screen :

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     Enter the filed values as explained in following table :


       Field name              Required User action and allowed values
                               /
                               Optional
       Permit                      R         Enter permit name
       Text                        R         Enter description of the permit

       Category                    R         Select category of permit from the list




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       Field name               Required User action and allowed values
                                /
                                Optional




       Order release                 O         Select required control on order releasing from
                                               the drop down list




                                               1 – while releasing order system will only warn


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       Field name              Required User action and allowed values
                               /
                               Optional
                                             about the issue of assigned permit to the order


                                             2 – Order release is possible after issuing the
                                             permit only


                                             (Blank) – No need for issue of Permit




       Order Completn              O         Select required control on order releasing from
                                             the drop down list




                                             1 – while completing order system will only

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       Field name                Required User action and allowed values
                                 /
                                 Optional
                                               warn about the issue of assigned permit to the
                                               order


                                               2 – Order completion is possible after issuing
                                               the permit only


                                               (Blank) – No need for issue of Permit
       Permit class                  R         System defaults Permit class
       Print                         O         Select the Print
       Not modifiable                O         N.A




     Click on


     If you want to write some more thing about the permit. You can use the
Long Text.



     Maintain required permit instructions and click on ICON




       Click on save button                                        to save the Permit.


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3.6 Characteristic
The pre-requisite for creating a Measuring Point is characteristic.


Creation of a Characteristic:
The Pre-requisite for creating a characteristic is “Unit of Measurement”, and almost
all standard “units of measurement” are available in the system. If a standard Unit of
Measurement is not available, contact administrator for creation of the same.

Trigger:
Format need for characteristic values and the need to display characteristics when
classifying master data


Output – Results                                                 Comments
List of characteristics                 Used to classify and identify objects




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     Double click or press Enter Key to reach the following screen




     In the initial screen, enter the values in the following fields:


       Field name              Required User action and allowed values
                               /
                               Optional
       Characteristics             R         Select characteristics & characteristic screen
                                             appear & (If you want to change a Existing
                                             Charecteristic) Select find by group & click. The
                                             next screen appears & select plant maint. From
                                             drop down list. If you want to create a new
                                             characteristic      please   enter   the     new
                                             characteristic name and then go to the menu
                                             bar “Charecteristic” and click on “new”




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       Field name              Required User action and allowed values
                               /
                               Optional




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       Field name              Required User action and allowed values
                               /
                               Optional




                                             After selecting the above screen double click
                                             you get the following screen. Then select the
                                             required characteristic & double click


       Change no                   O         If require fill
       Validity                    O         Select the date of validity from the calendar




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       Field name              Required User action and allowed values
                               /
                               Optional




     If the values are of standard type , values can be entered e.g., Speed of pumps
 1500 RPM, 3000 RPM, 1000 RPM, 750 RPM etc.,


     OR


     If Make is a characteristic, the values could be  Akay, KSB. Maag etc.,



        Click on


     The Characteristic is saved.

3.7 Measuring Points

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  Measuring Points:

  Measuring points in MY SAP ERP System describe the physical and/or logical
  locations at which a condition is described (for example, the feed water temperature
  of a boiler, or the number of run hours of a machine)

  In Plant Maintenance, measuring points are located on technical objects, in other
  words, on pieces of equipment or functional locations.

  Measuring points are classified into:

  Measuring points

  Normal inspection points like temperature, pressure readings

  Counters

  Counter is a provision in my SAP ERP to represent the wear and tear of an object,
  consumption, or the reduction of an object‟s useful life

  Counters can be used to accumulate the readings like equipment run hours,
Energy
  Consumption readings, etc.


Trigger:
A measurement or counter reading for any Equipment/ Functional location to capture
its current condition.


                          Business Process Procedure Overview
Measurement will be at a measuring point or a counter.




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End User Manual

                   Title: SAP PM
                     Module:             PLANT MAINTENANCE
                     Release:            ECC 6.0
                     Created by:         RAVINDER KUMAR
                     Created on:         23 Nov‟10




Output – Results                                                        Comments
Measurement Point created




     Creation of Measuring Point :
     Measuring Points can be created for Functional location and Equipment.


       ID: PM                           Title: Maintaining of Master data - Equipment
       Business process:                6.4.1.7 – Measuring Points
       Transaction                      Menu    path:   Logistics            Plant   maintenance
       code:IK01                        Management           of         Technical     Objects        
                                        EnvironmentMeasuring pointCreate (IK01)




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                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




     Case 1 : Normal Measuring Point


     As shown in the following screen, Select the transaction


     Double click or press Enter Key to reach the following screen




                                               Meas. Point category




     Screen fields data entry instruction:
       Field name              Required User action and allowed values
                               /
                               Optional
       Measurement                 R         Select IEQ for equipment /IFL for Functional
       Object                                Location. Now press enter key if corresponding
                                             field is not displayed as per IEQ or IFL

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                    Title: SAP PM
                      Module:           PLANT MAINTENANCE
                      Release:          ECC 6.0
                      Created by:       RAVINDER KUMAR
                      Created on:       23 Nov‟10




       Field name              Required User action and allowed values
                               /
                               Optional
       Equipment / fuct.loc         R         Equip/Flo code is to be selected
       Meas Pnt Cat                 R         Select required cato. Or use gen cato.
       Measuring       point O                Select if measuring point is counter or leave
       counter check box                      blank




     Press Enter Key or click on                      Details icon to reach the following
screen




     Screen fields data entry instruction:

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                    Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




       Field name                Required User action and allowed values
                                 /
                                 Optional
       Measurement                    O         Position      of     the      measuring   point   on   the
       Position                                 equipment or functional location.
       Characteristic                 R         Characteristic for Unit of Measurement
       Name
       Description of the R                     Detailed description of the measuring point
       measuring point
       Target Value                   O         Normal operating value should be entered:
                                                Example: 10.0kg/cm2
       Text                           O         Text can be entered: Example: Pressure under
                                                ambient condition.


If measuring point is normal measuring point and if data like max. and min. range is
to be given then click on Additional data tab. This data will determine for automatic
generation of notification whenever entered reading is beyond extreme limits.




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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




                     Additional data TAB




Go to : Additional data for entering Maximum and Minimum Values :


     Screen fields data entry instruction:
       Field name              Required User action and allowed values
                               /
                               Optional
       Upper Range Limit           O         The Maximum pressure condition
       Lower Range Limit           O         The Minimum pressure condition



       Click on


       The Measuring Point is saved.
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                      Module:           PLANT MAINTENANCE
                      Release:          ECC 6.0
                      Created by:       RAVINDER KUMAR
                      Created on:       23 Nov‟10




     Case 2 : Measuring Point as Counter




                       Check this box         if the
                       measuring  point         is a
                       counter




     Screen fields data entry instruction:
       Field name              Required User action and allowed values
                               /
                               Optional
       Measurement                  R         Select IEQ for equipment /IFL for Functional
       Object                                 Location. Now press enter key if corresponding
                                              field is not displayed as per IEQ or IFL
       Equipment / fuct.loc         R         Equip/Flo code is to be selected
       Meas Pnt Cat                 R         Select required cato. Or use gen cato.
       Measuring       point R                Select Check box

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                    Title: SAP PM
                     Module:           PLANT MAINTENANCE
                     Release:          ECC 6.0
                     Created by:       RAVINDER KUMAR
                     Created on:       23 Nov‟10




       Field name              Required User action and allowed values
                               /
                               Optional
       counter check box


     Press Enter Key to view the following screen




                                           Counter over reading /
                                           Reset value


                                                   Annual Estimate
                                                   Note : This is required for
                                                   Counter based planning




     Screen fields data entry instruction:




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                    Title: SAP PM
                        Module:           PLANT MAINTENANCE
                        Release:          ECC 6.0
                        Created by:       RAVINDER KUMAR
                        Created on:       23 Nov‟10




       Field name                Required User action and allowed values
                                 /
                                 Optional
       Measurement                    O         Position      of     the      measuring   point   on   the
       Position                                 equipment or functional location.
       Characteristic                 R         Characteristic for Unit of Measurement
       Name
       Description of the O                     Detailed description of the measuring point
       measuring point
       Counter Reading                O         Max displayable reading of the counter


       Annual Estimate                O         Annual Estimate of readings



       Click on
       The Measuring Point (Counter) is saved.

3.8 Work Center
Trigger:
Need identified for a new Work Center within a plant.


                            Business Process Description Overview
A work center is an organizational unit that defines where and when an operation
should be carried out within a plant. A work center is unique within a plant. Work
centers can be machines, people or production lines. Operations that need to be
executed are defined on a task list and executed at the corresponding user assigned
work center. This transaction enables the user to create basic data, set defaults,
assignments, and define capacities and scheduling data pertinent to a work center.

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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




Work centers contain default values that are copied or referenced in operations at the
time of task list creation. They also contain costing, scheduling and capacity data
required for leadtime scheduling and capacity planning.




Output – Results                                                Comments
New work center within a plant




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




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                   Title: SAP PM
                    Module:           PLANT MAINTENANCE
                    Release:          ECC 6.0
                    Created by:       RAVINDER KUMAR
                    Created on:       23 Nov‟10




3.9 Maintenance Planning


  Maintenance Plan (Single Cycle):

  Single cycle plan allows only one cycle frequency, whereas strategy plan allows
  multiple frequencies.

  Single cycle maintenance plan adopts exactly one time-based or performance
  based maintenance cycle, with interval at which the maintenance plan should be
  executed.



Trigger:
To plan maintenance events to occur in a regular, periodic manner, based on one
cycle parameter.


                          Business Process Procedure Overview
Maintenance plans merge the records of specific strategies, task lists, items and
measuring points (when necessary) to generate a recurring maintenance schedule for
the resultant orders which are copied from the task lists.
In addition, they can be used for condition-based maintenance which can generate
notifications or orders based on pre-established performance parameters.
There can be multiple maintenance items in a maintenance plan. A separate order will
generated from the plan for each item.




Output – Results                                                Comments
Maintenance plan is created.           The outputs of all three types of maintenance plans

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  • 1. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Project Sarthak Table of Content. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 1 of 241
  • 2. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 S.No. Page No. 1. Introduction ............................................................................................................ 4 2. Getting Started ....................................................................................................... 6 3. Master Data .......................................................................................................... 18 3.1 Functional Location ................................................................................................................... 18 3.2 Equipment .................................................................................................................................. 29 3.3 Equipment Bill of Material ........................................................................................................ 43 3.4 General maintenance Task lists .................................................................................................. 50 3.5 Work Permit ............................................................................................................................... 59 3.6 Characteristic ............................................................................................................................. 67 3.7 Measuring Points ....................................................................................................................... 71 3.8 Work Center ............................................................................................................................... 80 3.9 Maintenance Planning ................................................................................................................ 85 3.10 Maintenance Plan Scheduling .................................................................................................... 92 4. Maintenance Processing .................................................................................... 102 4.1 Measuring documents .............................................................................................................. 102 4.2 Breakdown Maintenance Process: ........................................................................................... 123 4.3 Preventive Maintenance ........................................................................................................... 160 4.4 Regular Maintenance : ............................................................................................................. 203 4.5 Calibration Process: ................................................................................................................. 209 5. Plant Maintenance Information System .......................................................... 217 5.1 Standard Reports ...................................................................................................................... 217 Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 2 of 241
  • 3. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 3 of 241
  • 4. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 1. Introduction SAP R/3 is an “integrated and industry-independent standard software” which covers integrates and connects all functional areas in a business. SAP AG defines integration as "defined communication". Although R/3 is designed for complete integration, it can also be used for a couple of business areas. SAP is the abbreviation for “Systems Applications and Products in Data Processing”. The purpose of this document is to provide an overview of SAP PM Functionality and the details of how the transactions are carried out in SAP R/3. The document has been organized as follows;  Master data maintenance required for PM module is covered first. Master data maintenance is the most important aspect as these data affects all the transaction where that Master data is used. It is very much controlled by authorizations as per the policy of the company.  As a PM user, you will be using various transactions to replicate day-to-day work in SAP R/3. So all the transactions, which are relevant to you for carrying out Plant Maintenance activities, are covered in this. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 4 of 241
  • 5. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Master data maintenance and transaction processes are explained with the help of SAP screen Shots. This will help you in executing the same perfectly. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 5 of 241
  • 6. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 2. Getting Started LOG ON: Select SAP Log in Icon On PC Desktop & press enter key or double click, Or follow the menu path as shown in following screen: Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 6 of 241
  • 7. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 The following screen will appear. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 7 of 241
  • 8. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Select Server and click on Log on icon Logging onto the SAP R/3 system  Sap R/3 systems are client systems. The client enables you to run several business operations at the same time in one SAP R/3 system.  Client is, in organizational terms, an independent unit in the system. Clients have their own data environment and therefore their own user master and transaction data, assigned user master records and chart off accounts and specific customizing parameters.  So that you log on to SAP R/3 system, you must have a master record created for you for corresponding client. For reasons of access Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 8 of 241
  • 9. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 protection, you must enter a password when you log onto the sap system. The system does not display the password you enter.  SAP R/3 system is available in several languages. Use the language input field to select the logon language for each session. Elements of the screen layout  Command Field: Use command field (hidden as default) to go to applications directly by entering the transaction code.  Standard Tool Bar: the push buttons in the standard tool bar are found on every screen in an SAP R/3 system. Any push buttons that cannot be used in a particular application are grayed out. If you place your Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 9 of 241
  • 10. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 cursor on a push button for a while the system displays a quick info text that explains the push button function.  The Application Tool bar: shows which functions are available in the current application.  A Tab page: provides a clearer overview of several information screens  Status bar: the status bar displays information on the current system status, for example. Warning or error messages  Menu bar: the menus shown here depend on which application you are working in.  Title bar: the title bar displays the functions that are available for the user.  Checkboxes: checkboxes enable you to select several options simultaneously within a group.  Radio Buttons: allow you to choose exactly one item form a selection. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 10 of 241
  • 11. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 The below shown screen gives you a detail explanation. Menu bar Standard toolbar Title bar Command Application toolbar Tab Page Input Fields Check boxes, Radio Buttons Status bar SAP Easy Access  Sap easy access is the standard entry screen displayed after the logon. You navigate through the system using the tree structure. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 11 of 241
  • 12. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 You are greeted by your logo in the right-hand part of the window Selecting Functions  You can call functions in the system as follows o Menu Option o Favourites o Entry in the SAP easy Access menu  “/n” ends the current session  “/i” delets the current session  “/oCV01N” opens a new session and branches out to the transaction specified (CV01N) Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 12 of 241
  • 13. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10  By entering “ search_sap_menu” in the command field, you can display menu paths for the desired SAP transaction. Command Field Menu SAP easy Access and Favorite List Field help : F1 and F4  Use F1 to display an explanation of fields, menus, functions and messages.  F1 Help also provides technical information on the relevant field. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 13 of 241
  • 14. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 F1 Help  Use F4 to display possible inputs . you can also access F4 help for a selected field using the button immediately to the right of that field. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 14 of 241
  • 15. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 F4 help User – Specific Personalization  The end user has many possibilities for personalizing the system. For example as shown in the screen below. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 15 of 241
  • 16. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 SAP – Symbols or icons Keyboard Keyboard Button Description Button Description Shortcut Shortcut Ctrl + Page First page Enter Key Enter/Continue Up Save to Ctrl + S Page Up Previous page database Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 16 of 241
  • 17. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Next page F3 Back Page Down Exit System Ctrl + Page Shift + F3 Last page Task Down Create New F12 Cancel None session Create shortcut Ctrl + P Print None on Desktop F1 Help Ctrl + F Find F1 Customize Local Ctrl + G Find next Alt + F12 Layout Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 17 of 241
  • 18. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 3. Master Data 3.1 Functional Location Functional locations are elements of a technical structure (for example, functional units within a system). Functional locations can be created according to the hierarchy, and can be structured based on the following criteria:  Functional  Process-related  Spatial Each functional location is managed independently in the system, to :  Manage individual data from a maintenance perspective for the object  Perform individual maintenance tasks for the object  Keep a record of the maintenance tasks performed for the object  Collect and evaluate data over a long period of time for the object Trigger: Functional locations need to be structured according to functional, process-related or spatial criteria. Whenever any new location identified we need to create Functional location. BUSINESS PROCESS PROCEDURE OVERVIEW A functional location is an organizational unit to structure the maintenance objects of a company according to functional, process-related or spatial criteria. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 18 of 241
  • 19. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 BUSINESS PROCESS PROCEDURE OVERVIEW A functional location represents the place at which equipment(s) can be installed and a maintenance task is to be performed. Output – Results Comments Functional location created Procedural Steps ID: PM Title: Maintaining of Master data – functional location Business process: Functional Location Transaction code: Menu path: Logistics Plant maintenance IL01, IL02 Management of Technical Objects  functional location  Create (IL01) Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 19 of 241
  • 20. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Description: Use this transaction for creating structured location Double CLICK on selected line or press Enter to get following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 20 of 241
  • 21. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Instructions In the initial screen, enter the values in the following fields: Field name Required User action and allowed values / Optional Functional location R Functional location code is to be entered as per the structure Structure indicator R Structure of func. With hierarchy level Fuct. loc. cat. R Type of fictional loc. “Press enter key“ or click on icon Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 21 of 241
  • 22. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Description R Functional Location. Name is to be entered (40characters). If the name exceeds, use long text. Ensure General data screen is open or click on GENERAL TAB Field name Required User action and allowed values / Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 22 of 241
  • 23. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Optional Weight O Weight of the Functional Location Size O Size of the Functional Location Start up date O Actual start date of usage Acquisition value O Value of the Functional Location at the time of acquiring Acquisition date O Date on which the Functional Location was acquired Manufacturer O Manufacturer of the Functional Location Manufacturing O Country, where the Functional Location was country manufactured Model number O Model number of the Functional Location supplied by the manufacturer Constr. Yr/mth O Year and month of Functional Location constructed Manuf Part No. O Part number of the Functional Location as supplied by the manufacturer Manuf Serial No. O Serial number of the Functional Location as supplied by the manufacturer After entering required data click on LOCATION TAB Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 23 of 241
  • 24. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Maintenance plant O Maintenance plant, where the Functional Location is located Location O Location of the Functional Location, for ex: Building where it is installed. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 24 of 241
  • 25. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Plant section O Further low level identification of location. Work center O Production work center, for blocking from production during maintenance work. ABC Indic O As detailed below : After entering required data click on ORGANISATION TAB TO GET FOLLOWING SCREEN : Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 25 of 241
  • 26. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Company code R R/3 will copy the respective company of the maintenance plant. Business area O For viewing profit and loss statement/area wise costing. Asset O Appropriate asset number should be assigned to the Functional Location. Cost center O All the costs incurred at the Functional Location level are collected at these cost centers level. Planning Plant O Maintenance planning plant, defaulted as that of maintenance plant. Planner group O Planner groups as per the maintenance planning activities. Maintenance work O Maintenance work center, currently represents center the departments like ME, EE, IE, CE & SE Catalog profile O For Functional Location history generation all the codes are maintained in a catalog profile. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 26 of 241
  • 27. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 After entering required data click on STRUCTURE TAB You will reach the following screen Field name Required User action and allowed values / Optional Functional Location O Functional location under which the Functional Location is functioning. Superior Functional O Superior Functional Location under which the Location Functional Location is functioning. Tech Ident. no O Technical identification number of the Functional Location. Const Type O Material of construction. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 27 of 241
  • 28. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Click on to Save and following message will be given by the system The Functional Location is saved. Through transaction code IL02, required functional location can be opened for editing If Functional location installation is to be changed, click on icon on structure tab, to get the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 28 of 241
  • 29. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 First dismantle the already existing installation and then input / select new installation location and click on Enter / Continue icon Click on to Save the changes made and following message will be given by the system. 3.2 Equipment A piece of equipment is an individual object that is to be maintained independently. Each piece of equipment is managed independently in the system, so that you can:  Manage individual data from a maintenance perspective for the object  Perform individual maintenance tasks for the object  Keep a record of the maintenance tasks performed for the object  Collect and evaluate data over a long period of time for the object Pieces of equipment can be installed and dismantled at functional locations. The usage times for a piece of equipment at a functional location are documented over the course of time. Trigger: Maintenance history needs to be captured for a physical technical object.Whenever any new Machine/Computer etc. Purchased we need to create Equipment Master. Correct Equipment Type has to be choosen always for proper functioning. BUSINESS PROCESS PROCEDURE OVERVIEW Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 29 of 241
  • 30. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 BUSINESS PROCESS PROCEDURE OVERVIEW This document describes how to create Equipment for use in PM functions. Equipment are master data to manage physical objects in PM and Customer Service. An Equipment master data object must be created here before it may be associated with a Functional Location object. Output - Results Comments Equipment Master created ID: PM Title: Maintaining of Master data - Equipment Transaction code: Menu path: Logistics Plant maintenance IE01, IE02, IE03, Management of Technical Objects  Equipment  Create (IE01) Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 30 of 241
  • 31. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Description: Use this transaction for creating & maintaining Equipment Double click or press Enter Key to reach the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 31 of 241
  • 32. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Instructions In the initial screen, enter the values in the following fields: Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 32 of 241
  • 33. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Equipment No in put is required as system creates an internal no, Valid on R By default system proposes current date, one can change to the appropriate valid from date. Equipment category R Appropriate equipment category to be selected from the list REFERENCE Equipment O Already existing equipment can be used to copy the data Material Not applicable this is required when a material/equipment link is required Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 33 of 241
  • 34. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Press Enter key or click on Enter / Continue icon to reach the following screen Enter the parameters as detailed below: in „General‟ screen Screen fields data entry instruction: Field name Required User action and allowed values / Optional Description R Equipment Name is to be entered (40characters). If the name exceeds, use long text. Object type O Type of machine ex: “select from list” Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 34 of 241
  • 35. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Weight O Weight of the equipment Size O Size of the equipment Start up date O Actual start date of usage Acquisition value O Value of the equipment at the time of acquiring Acquisition date O Date on which the equipment was acquired Manufacturer O Manufacturer of the equipment Manufacturing O Country, where the equipment was country manufactured Model number O Model number of the equipment supplied by the Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 35 of 241
  • 36. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional manufacturer Constr. Yr/mth O Year and month of equipment constructed Manuf Part No. O Part number of the equipment as supplied by the manufacturer Manuf Serial No. O Serial number of the equipment as supplied by the manufacturer Click on Location Tab to get the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 36 of 241
  • 37. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Maintenance plant R Maintenance plant, where the equipment is located Location O Location of the equipment, for ex: Building where it is installed. Plant section R Further low level identification of location. Work center O Production work center, for blocking from production during maintenance work. ABCD O As detailed below: Indicator Strategy A Critical B Important C Non-critical Now Click on Organization tab to get the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 37 of 241
  • 38. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Company code R R/3 will copy the respective company of the maintenance plant. Business area O For viewing profit and loss statement/area wise costing. Asset O Appropriate asset number should be assigned to the equipment. Cost center R All the costs incurred at the equipment level are collected at these cost centers level. Planning Plant O Maintenance planning plant, defaulted as that of maintenance plant. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 38 of 241
  • 39. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Planner group O Planner groups as per the maintenance planning activities. Maintenance work O Maintenance work center, currently represents center the departments like ME, EE, IE, CE & SE Catalog profile O For equipment history generation all the codes are maintained in a catalog profile. Now Click on Structure tab to get the following screen Click here for Installation at functional location Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 39 of 241
  • 40. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Functional Location O Functional location under which the equipment is functioning. Superior Equipment O Superior equipment under which the equipment is functioning. Tech Ident. no O Technical identification number of the equipment. Const Type O Material of construction. The field in the Function location blank, so it is to be selected for the Hierarchy Icon. Click on icon on structure tab, to get the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 40 of 241
  • 41. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 First dismantle the already existing installation and then input / select new installation location and click on Enter / Continue icon If you select the Superior Equipment Instead of Functional Location then that Equipment will be called SubEquipment. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 41 of 241
  • 42. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 WARRANTY END DATE WARRANTY START DATE Click on to Save the Equipment and following message will be given by the system Warranty is the commitment of the manufacturer, vendor, or retailer to guarantee services to a customer either free-of-charge or only charged in part, over a certain period of time. Warranty details of equipment can be incorporated during equipment creation or can be done in equipment data change transaction and can be viewed through display mode Whenever we try to create a notification or order, SAP system will alert with a warning message with warranty details if the equipment is still under warranty [period Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 42 of 241
  • 43. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 To accommodate different warranty conditions against different warranty services, a separate master warranty is to be created and the same is to be assigned to the equipment master data Field name Required User action and allowed values / Optional Master Warranty O N.A Begin guarantee O Start date of warranty Warranty end O End date of warranty 3.3 Equipment Bill of Material A “Bill Of Material” (BOM) is a complete, formally structured list of the components making up a technical object or an assembly. The list contains the object numbers of the individual components together with their quantity and unit of measure. The components can be stock or non-stock spares or assemblies, which in turn can be described using maintenance BOMs. BOMs are primarily used for the following purposes:  Structure description BOM describes the structure of a technical object or material. Using maintenance BOMs maintenance tasks can be planned  Assignment of spare parts BOM is used in plant maintenance to assign spares for a technical object or material. This is shown in the figure below: Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 43 of 241
  • 44. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Trigger: A piece of maintenance equipment requires a bill of material for maintenance purposes.Whenever any Equipment created we can create its BOM for Structuring. But Before creating Equipment BOM we need to create Material Master. BUSINESS PROCESS PROCEDURE OVERVIEW Create a bill of material for a piece of maintenance equipment to describe the equipment components, maintenance requirements or the assignment of spare parts. Output - Results Comments Equipment BOM created ID: PM Title: Maintaining of Master data – Equipment Business process: Bill of Material Transaction Menu path: Logistics Plant maintenance code:IB01, IB02 Management of Technical Objects Bill of materialEquipment BOMIB01 create Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 44 of 241
  • 45. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Description: Use this transaction for creating & maintaining Equipment bill of material Press Enter key or use mouse double click to get following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 45 of 241
  • 46. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Equipment no Plant BOM USAGE Press enter key In the initial screen, enter the values in the following fields: Field name Required User action and allowed values / Optional Equipment R Select Equipment for which BoM is being created Plant R Enter plant BOM usage R Select – 4 for Plant Maintenance Press Enter Key or Click on Enter / Continue icon To get the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 46 of 241
  • 47. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Enter the parameters as detailed below : in „Material‟ screen Screen fields data entry instruction: Field name Required User action and allowed values / Optional Item category R Select Item Category Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 47 of 241
  • 48. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Component R Select item code Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 48 of 241
  • 49. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Component R System defaults description of selected description component Quantity R Enter installed quantity Units R System defaults UOM of selected component Click on to save the entered data Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 49 of 241
  • 50. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 3.4 General maintenance Task lists Task Lists. Task list is defined as the set of work instructions that will help a maintenance planner schedule his day-to-day job in a predefined manner Maintenance task lists describe a sequence of individual maintenance activities, which must be performed repeatedly within a company. Task lists are used to standardize these recurring work sequences and to plan them more effectively. Task lists can be grouped, for example in to two groups - "Inspection" and "Mechanical Repairs". The individual maintenance task lists within the group "Mechanical Repairs" and are identified by the task list counter numbers 01 and 02 as shown in following fig. General Maintenance Task List This type of task list is generic in nature i.e. the same general task list can be used both for equipment and functional location and also for more than one equipment or functional location of the same type or different types. Similar general task lists can be grouped and several individual general maintenance task lists can be created. General task lists can be used to reduce the time spent creating individual functional location/equipment task lists. Trigger: Need to prepare a sequence of activities that must be repeatedly performed within a company. BUSINESS PROCESS PROCEDURE OVERVIEW Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 50 of 241
  • 51. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 BUSINESS PROCESS PROCEDURE OVERVIEW Maintenance task lists describe a sequence of individual maintenance activities which must be repeatedly performed within a company. They are used to standardize repetitive work processes, to plan them more effectively, and to save time when creating maintenance orders and maintenance plans. Output – Results Comments General Task List created For General Task Lists ID: PM Title: Maintaining of Master data - Functional location Business process: General Task List Transaction code: Menu path: Logistics Plant IA05 maintenancepreventive maintenance Work schedulingtask listGeneral maintenance Task lists  Create (IA05) Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 51 of 241
  • 52. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Description: Use this transaction for creating & maintaining General task list Press Enter Key to get the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 52 of 241
  • 53. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Group R Enter a group name (8 characters only) Profile R PDIL Key date R Date from which the task list is to be used Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 53 of 241
  • 54. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Enter the field value according to the following table Field name Required User action and allowed values / Optional Group CNTR R System defaults grp cntr is to be entered Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 54 of 241
  • 55. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Work Center O Select responsible work center from the list Usage O Select 4 for plant maintenance R Select 4 for plant maintenance Status Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 55 of 241
  • 56. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Click on operation tab Following screen can be viewed Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 56 of 241
  • 57. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 In the initial screen, enter the values in the following fields: Field name Required User action and allowed values / Optional Work center R Select work center Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 57 of 241
  • 58. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Plant code R Define plant code like for Noida Engineering= 1100 Ctrl key R Pm 01 for internal operations & PM 03 for external operations Operation O Describe the operation to be carried out description Work O System will automatically calculate by calculation key UN O Unit of measurement for mh NO O No of persons required to perform the activity Duration O Duration of Operation Unit O Unit of measurement for duration C O Calculation key –2 ( for calculating duration ) Repeat the same above operation for required no of activities Select components tab for allotting spares required for that activity. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 58 of 241
  • 59. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Material O Select required item code Qty O Enter the required qty Click on to save the task list. 3.5 Work Permit Permits are to ensure that special approval must be obtained before maintenance orders are executed. Permits can be assigned to the following objects:  Technical objects (functional locations and equipments)  Maintenance orders Different types of work permit are required Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 59 of 241
  • 60. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Permits can be grouped into permit categories, like  Work permit – General jobs  Hot work permit - Hot job  Confined space work permit - permit to work at confined areas  High reach work permit-Permit to work at elevated places Trigger: A regulation or condition needing to be observed when maintenance work is being performed. BUSINESS PROCESS PROCEDURE OVERVIEW A permit is a regulation or condition that must be observed when maintenance work is to be performed on a technical object. The creation of the permit master record is covered in this procedure. The permit can be attached to a Functional Location, Equipment master, or directly to a work order. The requirement can be observed at the release or the completion of a work order. The permit can only be for reference, provide a warning, or cause an error message unless issued. Output – Results Comments Permit master created Master record can be viewed again by selecting row and choosing details. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 60 of 241
  • 61. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 ID: PM Title: Maintaining of Master data – Work Permits Business process: Work permits Transaction code: Menu path: Logistics Management of tech. IPMD objects Environment  IPMD permits Select the transaction as shown in the following screen Press enter key or double click to reach the following screen Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 61 of 241
  • 62. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 To view the next screen press Enter key or click on icon AND THEN ON to view the following screen : Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 62 of 241
  • 63. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Enter the filed values as explained in following table : Field name Required User action and allowed values / Optional Permit R Enter permit name Text R Enter description of the permit Category R Select category of permit from the list Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 63 of 241
  • 64. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Order release O Select required control on order releasing from the drop down list 1 – while releasing order system will only warn Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 64 of 241
  • 65. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional about the issue of assigned permit to the order 2 – Order release is possible after issuing the permit only (Blank) – No need for issue of Permit Order Completn O Select required control on order releasing from the drop down list 1 – while completing order system will only Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 65 of 241
  • 66. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional warn about the issue of assigned permit to the order 2 – Order completion is possible after issuing the permit only (Blank) – No need for issue of Permit Permit class R System defaults Permit class Print O Select the Print Not modifiable O N.A Click on If you want to write some more thing about the permit. You can use the Long Text. Maintain required permit instructions and click on ICON Click on save button to save the Permit. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 66 of 241
  • 67. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 3.6 Characteristic The pre-requisite for creating a Measuring Point is characteristic. Creation of a Characteristic: The Pre-requisite for creating a characteristic is “Unit of Measurement”, and almost all standard “units of measurement” are available in the system. If a standard Unit of Measurement is not available, contact administrator for creation of the same. Trigger: Format need for characteristic values and the need to display characteristics when classifying master data Output – Results Comments List of characteristics Used to classify and identify objects Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 67 of 241
  • 68. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Double click or press Enter Key to reach the following screen In the initial screen, enter the values in the following fields: Field name Required User action and allowed values / Optional Characteristics R Select characteristics & characteristic screen appear & (If you want to change a Existing Charecteristic) Select find by group & click. The next screen appears & select plant maint. From drop down list. If you want to create a new characteristic please enter the new characteristic name and then go to the menu bar “Charecteristic” and click on “new” Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 68 of 241
  • 69. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 69 of 241
  • 70. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional After selecting the above screen double click you get the following screen. Then select the required characteristic & double click Change no O If require fill Validity O Select the date of validity from the calendar Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 70 of 241
  • 71. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional If the values are of standard type , values can be entered e.g., Speed of pumps  1500 RPM, 3000 RPM, 1000 RPM, 750 RPM etc., OR If Make is a characteristic, the values could be  Akay, KSB. Maag etc., Click on The Characteristic is saved. 3.7 Measuring Points Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 71 of 241
  • 72. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Measuring Points: Measuring points in MY SAP ERP System describe the physical and/or logical locations at which a condition is described (for example, the feed water temperature of a boiler, or the number of run hours of a machine) In Plant Maintenance, measuring points are located on technical objects, in other words, on pieces of equipment or functional locations. Measuring points are classified into: Measuring points Normal inspection points like temperature, pressure readings Counters Counter is a provision in my SAP ERP to represent the wear and tear of an object, consumption, or the reduction of an object‟s useful life Counters can be used to accumulate the readings like equipment run hours, Energy Consumption readings, etc. Trigger: A measurement or counter reading for any Equipment/ Functional location to capture its current condition. Business Process Procedure Overview Measurement will be at a measuring point or a counter. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 72 of 241
  • 73. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Output – Results Comments Measurement Point created Creation of Measuring Point : Measuring Points can be created for Functional location and Equipment. ID: PM Title: Maintaining of Master data - Equipment Business process: 6.4.1.7 – Measuring Points Transaction Menu path: Logistics Plant maintenance code:IK01 Management of Technical Objects  EnvironmentMeasuring pointCreate (IK01) Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 73 of 241
  • 74. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Case 1 : Normal Measuring Point As shown in the following screen, Select the transaction Double click or press Enter Key to reach the following screen Meas. Point category Screen fields data entry instruction: Field name Required User action and allowed values / Optional Measurement R Select IEQ for equipment /IFL for Functional Object Location. Now press enter key if corresponding field is not displayed as per IEQ or IFL Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 74 of 241
  • 75. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Equipment / fuct.loc R Equip/Flo code is to be selected Meas Pnt Cat R Select required cato. Or use gen cato. Measuring point O Select if measuring point is counter or leave counter check box blank Press Enter Key or click on Details icon to reach the following screen Screen fields data entry instruction: Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 75 of 241
  • 76. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Measurement O Position of the measuring point on the Position equipment or functional location. Characteristic R Characteristic for Unit of Measurement Name Description of the R Detailed description of the measuring point measuring point Target Value O Normal operating value should be entered: Example: 10.0kg/cm2 Text O Text can be entered: Example: Pressure under ambient condition. If measuring point is normal measuring point and if data like max. and min. range is to be given then click on Additional data tab. This data will determine for automatic generation of notification whenever entered reading is beyond extreme limits. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 76 of 241
  • 77. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Additional data TAB Go to : Additional data for entering Maximum and Minimum Values : Screen fields data entry instruction: Field name Required User action and allowed values / Optional Upper Range Limit O The Maximum pressure condition Lower Range Limit O The Minimum pressure condition Click on The Measuring Point is saved. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 77 of 241
  • 78. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Case 2 : Measuring Point as Counter Check this box if the measuring point is a counter Screen fields data entry instruction: Field name Required User action and allowed values / Optional Measurement R Select IEQ for equipment /IFL for Functional Object Location. Now press enter key if corresponding field is not displayed as per IEQ or IFL Equipment / fuct.loc R Equip/Flo code is to be selected Meas Pnt Cat R Select required cato. Or use gen cato. Measuring point R Select Check box Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 78 of 241
  • 79. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional counter check box Press Enter Key to view the following screen Counter over reading / Reset value Annual Estimate Note : This is required for Counter based planning Screen fields data entry instruction: Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 79 of 241
  • 80. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Field name Required User action and allowed values / Optional Measurement O Position of the measuring point on the Position equipment or functional location. Characteristic R Characteristic for Unit of Measurement Name Description of the O Detailed description of the measuring point measuring point Counter Reading O Max displayable reading of the counter Annual Estimate O Annual Estimate of readings Click on The Measuring Point (Counter) is saved. 3.8 Work Center Trigger: Need identified for a new Work Center within a plant. Business Process Description Overview A work center is an organizational unit that defines where and when an operation should be carried out within a plant. A work center is unique within a plant. Work centers can be machines, people or production lines. Operations that need to be executed are defined on a task list and executed at the corresponding user assigned work center. This transaction enables the user to create basic data, set defaults, assignments, and define capacities and scheduling data pertinent to a work center. Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 80 of 241
  • 81. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Work centers contain default values that are copied or referenced in operations at the time of task list creation. They also contain costing, scheduling and capacity data required for leadtime scheduling and capacity planning. Output – Results Comments New work center within a plant Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 81 of 241
  • 82. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 82 of 241
  • 83. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 83 of 241
  • 84. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 84 of 241
  • 85. End User Manual Title: SAP PM Module: PLANT MAINTENANCE Release: ECC 6.0 Created by: RAVINDER KUMAR Created on: 23 Nov‟10 3.9 Maintenance Planning Maintenance Plan (Single Cycle): Single cycle plan allows only one cycle frequency, whereas strategy plan allows multiple frequencies. Single cycle maintenance plan adopts exactly one time-based or performance based maintenance cycle, with interval at which the maintenance plan should be executed. Trigger: To plan maintenance events to occur in a regular, periodic manner, based on one cycle parameter. Business Process Procedure Overview Maintenance plans merge the records of specific strategies, task lists, items and measuring points (when necessary) to generate a recurring maintenance schedule for the resultant orders which are copied from the task lists. In addition, they can be used for condition-based maintenance which can generate notifications or orders based on pre-established performance parameters. There can be multiple maintenance items in a maintenance plan. A separate order will generated from the plan for each item. Output – Results Comments Maintenance plan is created. The outputs of all three types of maintenance plans Last changed on: Last changed by: Version: Page: (23/11/2010) RAVINDER KUMAR 1.0 85 of 241