Plant Maintenance in SAP A functional perspective

Transcription

1 breaking through barriers to progress Plant in SAP A functional perspective By Gopinath an award winning '2004 Future 50 Company' W. Corporate Drive Suite 120 Brookfield, WI

2 SAP R/3 - Overview Overview: R/3 Overview and Integration TeamSAP Academy R/3 Overview & Integration Getting Started SD Sales & Distribution MM Materials PP Mgmt Production Planning R/3 FI Financial Accounting CO Controlling AM Asset Mgmt QM Client / Server PS Quality Project Mgmt System PM ABAP WF Plant Main- Workflow tenance HR IS Human Industry Resources Solutions R/3 Applications Support & Services System-Wide Concepts R SAP AG 2

3 SAP R/3 Modules Logistics PP Production Planning QM MM Material Manag. Quality Manag. PM Plant Maint. SD Sales & Distrib. R/3 FI Financial Accounting Client / Server ABAP HR Human Resources. IS Industry Solutions CO Controlling WF Workflow TR Treasury PS Project System Accounting Human Resources Cross Application Functions R SAP AG 3

4 What Is Integration? SD MM PP QA PM HR R/3 FI CO AM PS WF IS Common organizational structures throughout the system Seamless processing of common data between applications Comprehensive support and reference tools Common reporting features and functionality Object and application linking and overall system communication R SAP AG 4

5 Organization of Plant : Business Scenario Plant is an integral part of the company and has numerous links to other enterprise areas. Depending on the company structure, maintenance planning is either plantbased (decentralized) or cross-plant (centralized). 5

6 Structure of Plant EQM Technical Data Functional locations Equipment Assemblies Bills of material Networks of technical objects PRM Preventive Task lists plans WOC Processing notifications orders PMIS Plant Information System CRP Work Centers and Capacity work centers 6

7 Concept of Plant Master data Characteristics Classes Equipment / functional locations Cost records Cost center work centers Bills of material Task lists strategies Planning notification plans Order processing Material reservation Material issues order Capacity load Time confirmation Purchase orders / release order Purchase requisition Goods receipt / invoice receipt 7

8 Organizational Structures in Plant General Organizational Units in Logistics Client Company code Plant Location-Based Organizational Units plant Location Plant section For example, site, building, coordinate For example, production area, plant engineer Planning-Based Organizational Units planning plant planner groups work centers For example, foreman, work scheduling For example, mechanics 8

9 Cross-Plant Plant 1200 Plant 1300 requirement requirement Workshops Plant 1000 Warehouse Planning of maintenance requirements requirement Workshops Material 9

10 Work Centers work centers For example: Welding Metalworking Mechanics 10

11 Work Center: Contents Basic data General data Capacity data Capacity categories Scheduling Capacity / pool capacity Available capacity profile Links Activity types Activity types Activity types Cost center Work center Person Staffing assignment Qualification Staffing assignment Staffing assignment T i m e 11

12 Work Center: Main Functions Work Center Default values for task lists and orders Costing data Scheduling data and available capacity Task list // order Costing 2, , , Lead time scheduling Capacity planning 12

13 Functional Location Functional location = multi-level, hierarchical structure, organized according to... Spatial Technical Functional Criteria 13

14 Criteria for Functional Locations When is a functional location created? Execution of maintenance tasks Recording of maintenance tasks Data collection over long periods of time Cost monitoring by area What effect do the usage conditions have on the likelihood of damage to the installed aggregates? 14

15 Automatic Assignment Upon Creation Existing functional locations C1-M Mechanical cleaning C1 Clarification plant C1-B Biological cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station New functional locations C1-M01-2 Ventilator Ventilator C1-M02-2 Ventilator C1-B01-1 Pump 1 C1-B02-2 Filter cell 15

16 Example of Functional Location Structure C1-M Mechanical cleaning C1 Clarification plant C1-B Biological cleaning C1-M01 Sand trap C1-M02 Oil/fat trap C1-B01 Pump plant C1-B02 Filtering station C1-M01-1 Reservoir C1-M01-2 Ventilator C1-M01-3 Sand dredger C1-M02-1 Reservoir C1-M02-2 Ventilator C1-M02-3 Fat dredger C1-B01-1 Pump 1 C1-B01-2 Pump 2 C1-B02-1 Ventilator C1-B02-2 Filter cell C1-B02-1A Valve 1 C1-B02-1B Valve 2 C1-B02-2A Inlet C1-B02-2B Filtrate level C1-B02-2C Outlet C1-B02-2A/1 C1-B02-2A/2 C1-B02-2C/1 C1-B02-2C/2 Valve 1 Valve 2 Valve 1 Valve 2 16

17 Criteria for Equipment Master Record When is a piece of equipment created? Management of individual data Recording of maintenance tasks Object-based recording of costs Evaluation of technical data Recording of usage times 17

18 Equipment Master Record Equipment master record General Location Equipment usage Classification Documents / technical drawings Multilingual texts Location A Location B List X X X X X X X Organization Structure Address / partner Measuring points / counters Permits Internal note

19 Bills of Material in Company Production bill of material Engineering/design bill of material bill of material Costing bill of material 19

20 Breakdown : Business Scenario For breakdown maintenance, the data required for the other business processes needs to entered quickly and easily so that the subsequent steps can be executed. 20

21 Business Process: Breakdown 1 Notification Technical object Description Date Malfunction 2 1 Planning Work to be performed Internal/external resources Material Tools 3 Scheduling Order release Printout Capacity leveling Availability check 4 2 Execution Planned/unplanned material withdrawal External procurement 5 3 Completion Time confirmation Order settlement Technical completion Technical confirmation History Material usage, orders, notifications, PMIS, usage list 21

22 Order: Putting in Process Status 'RELEASED' Put in process Order papers 22

23 Time Confirmations Initial screen Scope Individual entry Collective entry Collective entry using operation list Overall completion confirmation Partial confirmation Final confirmation Reversal option 23

24 Order: Technical Completion Order Limited ability to change order Status 'Technically completed' Define location and account assignment data Create settlement rule Set deletion flag for purchase requisitions Close open reservations Close open capacities 24

25 Cycle for Corrective 1 Notification Technical object Description Date Malfunction 2 Planning Work to be performed Internal/external resources Material Tools 3 Scheduling Order release Printout Capacity leveling Availability check 4 5 Execution Completion Planned/unplanned material withdrawal External procurement Time confirmation Order settlement Technical completion Technical confirmation History Material usage, orders, notifications, PMIS, usage list 25

26 Definition of Notification Describes the condition of a maintenance object, particularly a malfunction Malfunction report Describes a maintenance activity already performed (purely technical documentation) Activity report Requests a maintenance service/task request 26

27 Notification: Structure Notification Date / time / reported by Description Object: Functional location Equipment Assembly Material serial number Location data Breakdown / availability Notification Text items Damage location Damage Cause of damage Activities Activity Execution factors Tasks Dates Task description 27

28 iobject information Plant - Overview Notification: Object Information Orders dates Notifications Documents Processing days Links Structure list Breakdowns 28

29 Select Notifications Why? Find particular maintenance notification Process several maintenance notifications simultaneously Restrict planning worklist Scope Notification Notification items Tasks Customizing Selection conditions Field selection Functions Different sorting Select / delete complete list Different list fields, internal display variant Display breakdowns graphically Excel processing 29

30 Print Notifications notification Fax transfer Notification overview Breakdown report Activity report 30

32 Creation of Orders Direct creation of order order / notification Creation of order based on notification notification order Combination of maintenance notifications for maintenance order Entry of order with subsequent activity report Automatic generation of maintenance order from maintenance item notification notification notification order item order notification order 32

33 Characteristics of Orders Flexibility of order processing Object reference Single object Object list Period of validity Single order Standing order Execution Internal processing External processing 33

34 Stock Material - Process Flow Component assignment Material reservation Availability check May Order release Automatic availability check May Printing Goods issue 34

36 Resource Planning: Availability Check Plant stock Material withdrawal for cost center Inward stock movement from purchase order Today Stock transfer to other plant Inward stock movement from internal production Maximum ATP quantity Requirement date Stock profile Safety stock 36

37 Order: Printing order Fax transfer Job ticket Operation control ticket Pick list Object list Time ticket Material withdrawal slip Confirmation slip 37

38 Order Completion Confirmation: Times / Activities Times Individual entry Collective entry Overall completion confirmation Time sheet (CATS) Activities Activity reports Overall completion confirmation Confirmation texts Object changes Measurement readings 38

39 Questions?? Contact Details : mail id : gthangavelu@darylflood.com Cell : Residence :