SAP Plant Maintenance.pptx

SECTION TITLE
PLANT
MAINTENANCE
Last revised: Aug 22, 2022

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1
Contents (PM)
 Introduction to SAP Plant Maintenance
 Features of SAP Plant Maintenance
 Functions of SAP Plant Maintenance
 PM Organization Structure
 PM Master Data
 PM Business Processes
 Other modules / external integration with SAP PM
 Conclusion
 References

SECTION TITLE
INTRODUCTION
TO
SAP PM

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3
Introduction
SAP PM (Plant Maintenance) is a module in SAP ERP Central Component (ECC) as a part of
logistics functionality that provides companies with the functionalities relevant to the maintenance of
the technical objects such as equipment, functional locations etc., which are assets to the company.
The primary goal of SAP PM is to make sure that the equipment / functional locations are being
properly carried out with maintenance both in terms of preventive as well as reactive maintenance.
The maintenance process is mainly categorized into Planned (Preventive) and Unplanned
(Corrective) maintenance. These two categories can be further categorized as per the business
requirements by defining relevant order types that’s mainly done for effective reporting.
SAP PM integrates with other ECC components like Production Planning (PP), Sales and
Distribution (SD), Materials Management (MM), Quality Management (QM), Finance and Controlling
(FICO) and Human Capital Management (HCM).
The scope of Plant Maintenance varies greatly from company to company and may limit to a simple
maintenance processes such as Preventive Maintenance, Breakdown Maintenance etc., or may
extend to the usage of several functionalities such as Refurbishment Process, Permits &
Warranties, Work Clearance Management, Warranty Claim Processing and further into Customer
Service.
SAP PM process implementation requires several master data which includes but nor limited to
Work Centers, Equipment, Functional Locations, Bills of Material, Maintenance Plans, Measuring
Points & Counters, Permits, Warranties etc.

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Features and Purpose of Plant Maintenance
Salient Features of SAP PM
 Covers all types of Maintenance Processes
 Ensures timely maintenance using maintenance plans
 Helps to speed up the maintenance activities through maintenance planning.
 Reduces the repetitive work of entering data through usage of Master Data and Task Lists.
 It helps organizations to deal with various business aspects like Maintenance Planning,
Maintenance Execution and Maintenance Costing.
Purpose of SAP PM
Primary
 Minimum Breakdowns
 Maintain plant in good working condition
 Lower maintenance costs with time
 Optimum usage of Assets
 Maximize Asset performance
 Increase on-time availability of assets
 Good information system
Secondary
 Maintenance Planning
 Resource Planning
 Operations Planning
 Material Requirements Planning
 Cost Planning
 Preventive Maintenance Planning

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Features and Purpose of Plant Maintenance
Plant Maintenance comprises the following activities:
1. Inspection: All measures which establish the actual condition of a technical system
2. Preventive maintenance: All measures which maintain the ideal condition of a technical system
3. Repair: All measures which restore the ideal condition of a technical system
4. Other measures taken using the maintenance organization
SAP Plant Maintenance covers following purposes:
 General Maintenance (Corrective/Unplanned)
 Breakdown Maintenance (Corrective/Unplanned/Breakdown)
 Preventive maintenance (Preventive/Planned) : - Time-Based
- Performance Based
- Condition Based
 Refurbishment Process
 Calibration Process
 Shutdown Maintenance

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Features of Plant Maintenance
Elements of Plant Maintenance
 Technical Objects
 Unplanned Maintenance
 Planned Maintenance
 Maintenance Planning: (Operations, Manpower and Duration)
 Maintenance Execution
 Maintenance Costing
Advantages of Plant Maintenance
 Increased asset life span
 Reduced downtime of Equipment/Functional Locations
 Increased MTBR (Mean Time Between Repair)
 Reduced MTTR (Mean Time to Repair)
 Increased efficiency.
 Effective costing – Planned Vs. Actual.

SECTION TITLE
FUNCTIONS
OF
SAP PM

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Functions of Plant Maintenance
SAP PM (Plant Maintenance) Module is a SAP ERP component that helps manage a plant’s assets
through maintenance activities that are carried out as and when required. It is a part of SAP ECC’s
logistics functions which consists of several components and sub-components. The most prominent and
widely used components are Technical Objects, Maintenance Order Management and Preventive
Maintenance.
The core functions of SAP Plant Maintenance is defined with three terms, namely Inspection, Repair and
Maintenance (Preventive). Several functionalities are build based on the core functions such as
Corrective Maintenance, Preventive Maintenance, Calibration Maintenance, Refurbishment Process,
and Shutdown Maintenance. Functions such Permits, Warranties, Measuring Points & Counters etc. are
used to establish the above functionalities.

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9
Organization Structure:
A typical Organization Structure for
Plant Maintenance module is
shown beside.
The Organizational units are mainly
the Maintenance plant and the
Maintenance Planning Plant which
are again makes up the hierarchy
for the smaller organizational units
as shown below.

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10
SAP PM organizational structure includes the following organizational units:
 Client: Client is highest level of an organization structure. It includes all the subsidiaries within one
corporate group.
 Company Code: Each subsidiary is represented with a company code in SAP system. Each
company code has its own balance sheet and P&L statement.
 Plant: Plant is one the most important structures in SAP PM organizational structure. It is the place
where manufacturing of products takes place. One company code can have multiple plants.
 Maintenance Plant: Organizational unit where operational systems are installed is called a
maintenance plant.
 Maintenance Planning Plant: This is a plant at which the maintenance operations are planned. It is
possible that requirements come from own plant or from another maintenance plant assigned to the
maintenance planning plant. In most cases, the maintenance planning plant is same as the
maintenance plant.
 Plant section: A maintenance plant can be divided into subparts which are known as plant sections.
For example, a plant can be divided into production area, store, electrical substation, etc.
 Location: Location is the place where a functional object is physically installed in a plant section. It
is used for informative purposes.
 Maintenance Planner Group: It is a group of employees responsible for planning and processing of
maintenance tasks in a plant. A different maintenance planner group is created for each plant.
 Work Center: Work center is an organizational unit where maintenance activities are performed. It
belongs to master data. Work center defines where and when the maintenance operation will be
performed. Work center is assigned in task list, maintenance order, and maintenance operation line
items. Machine/group of machine or person/group of people can be represented as a work center.

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SAP PM - Master Data
Master data in SAP Plant Maintenance comprise of the following. These master data are used in PM
business processes and thus eases the use of functionalities.
 Work Centers
 Functional Locations
 Equipment
 Bills of Material
 Task Lists
 PRTs
 Maintenance Plans / Maintenance Items
 Permits
 Warranties
 Measuring Points, Counters & Measurement Documents
SAP PM - Key Data
The below data used in SAP PM is termed as key data which is configured in the system along with PM
Organization Structure. The reporting in SAP Pm is heavily relied on this key data.
 Planner Groups
 Plant Sections
 Locations
 ABC Indicators

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General Maintenance
General Maintenance involves the maintenance of any equipment which doesn’t have a direct impact
on the production efficiency, yet requires to carry out the maintenance activity in order to maintain
optimal working conditions in a plant.
Examples include the maintenance required for computers, air conditioners in the office environment
or any other equipment that indirectly aid in the production environment etc.
Breakdown Maintenance
As the name says it, breakdown maintenance involves in the breakdown of any equipment thus
directly effecting the production efficiency. Hence, a breakdown is considered critical and the
breakdown duration is being calculated for further analysis every time when a breakdown occurs.
SAP PM facilitates the maintenance order with a breakdown indicator for this purpose.
Breakdown durations are critical to record since they directly help in designing Preventive
Maintenance Plans.
This process is used when a machine or equipment is under breakdown resulting the production
stoppage – thus requiring immediate attention by the maintenance department. The issue is
addressed with highest priority and immediate corrective actions are put in place to being down the
production situation to normal.

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Preventive Maintenance
Preventive Maintenance is used to carry out the planned maintenance on equipment or functional
locations. To achieve this maintenance plans are designed and maintained in the SAP for respective
equipment or functional locations, so that the system generates maintenance orders automatically as and
when required.
To ease the process, the maintenance plans are associated with Task Lists and Bills of Materials to
enable the order to automatically derive the operations and components for each maintenance plan.
The maintenance plan can be either periodic or condition based – thus SAP system facilitates
functionalities such as Single Cycle, Strategies to perform Time-Based, Performance-Based and
Condition-Based maintenance processes.
Refurbishment Process
Refurbishment Process involves the refurbishment of an equipment. This means – when an
equipment is in damaged status that there high cost and major components replacement is involved
for it’s repair – the refurbishment process is adopted.
Here, the damaged equipment is issued for the maintenance which after the repairs is brought back to
the inventory with refurbished status. The status is controlled through valuation type of material
through MM module. The valuation of the damaged material is increased when it turns into
refurbished material since the maintenance costs are settled to the refurbished material

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Integration with Other Modules of SAP
PM–PS :
When the maintenance activities are carried out through projects using PS modules. The
WBS elements are used as reference and the cost involved in carrying out the maintenance
activities are settled to the WBS elements
PM–FICO :
The cost of the maintenance order is settled to the cost elements such as Cost Centers.
There is a tight integration between plant maintenance and controlling modules since all
maintenance orders are to be settled in the end either to a cost center or to COPA.
PM–MM :
The material/ service requirement is mentioned in Maintenance Order which leads to
generation of PR. This PR is converted to PO by PM. The goods are issued against
reservations flowing from PM orders. Also, the material requirements are identified and
integrated to the MM module through MRP thus generating the Reservations/Independent
requirements based on the stock/non-stock material.
The material requirement leads to the creation of PR and further a PO, with a subsequent
Goods Receipt of the material – which is then issued to the maintenance order by the
inventory.
The external services required are procured through Service PO and subsequent acceptance
of the service through Service Entry Sheets.

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To Be – PM Organization Structure
Organization Structure
Maintenance plants required : 4
Planning Plants Required : 4
Planner Groups : Yes (Data to collect)
Plant Sections : Yes (Area wise)
ABC Indicators : Yes
Master Data required:
Work Centers ,
Functional Locations, Equipment, Bills of Material,
Classification (Classes & Characteristics),
Maintenance Plans, Task Lists,
Master Inspection Characteristics

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To Be – PM Organization Structure
Business Processes:
General Maintenance
Breakdown Maintenance
Preventive Maintenance
Calibration Maintenance
Refurbishment process (To be confirmed with business)
Work Order Management:
• Order through Notification
• Order through Maintenance plan
• Manual Order creation and processing.

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Work Order Cycle
ME53N –
Display PR
Notification
Maintenance
Order
Availability
Check
Schedule and
release
Maintenance
Order
Order
confirmation
Order closed
Purchase
Order
Goods
Receipt
Purchase
Requisition
IW21 – Create
IW22 – Change
IW23 – Display
IW28 – Report
IW31 – Create
IW32 – Change
IW33 – Display
IW38 – Report
IW32 –
In Order
Change mode
MIGO –
Goods Receipt
ME23N –
Display PO
IW32 –
In Order
Change mode
IW41 –
Work Confirmation
IW32 –
In Order
Change mode

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SAP Plant Maintenance is an important maintenance tool which will
be very useful in the maintenance of assets of all plants – aids in the
timely maintenance of the asset with pre-defined operations, planned
manpower and the spare parts facilitating the capture of the costs
through out the process thus making all the data available for further
analysis.
Performing preventive maintenance prolongs the life of your
equipment, reduces downtime, decreases reactive maintenance
requests, helps you manage compliance and inspection needs, and
prevents costly emergency repairs from occurring.
Conclusion
References
 www.help.sap.com
 www.google.com

SAP Plant Maintenance.pptx

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SAP Plant Maintenance.pptx