Consulting

Transforming

Enterprises

Project Name

JK Cement

Title

Breakdown Maintenance

Version

1.0s

Document ID

JK_BBP_PM_BP_0500_V1.0

Author

Akhilesh Kumar Singh

Reviewed By

XXXXXXX XXXXX

Date

01.11.2012

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

IMPLEMENTATION_BLUE PRINT
Business Process Details
Module

Plant Maintenance
Process
Sub Process /
No

Breakdown Maintenance
Breakdown Maintenance & Civil Maintenance

Description

Breakdown Maintenance & Civil Maintenance

Sr No
1.1
1.2

JK_BBP_PM_BP_050
0

Business Process Explanation

As Is Process General Explanation
Explanation of Proposed Process
In case of any Break down, Production User/CCR/Maintenance Engrr.
generates a Maintenance Notification of Notification type M2. He records the
Break down occurrence time, technical object (Equipment/ Function location)
affected, & damage or any kind of observation found. Online information of
Break down & status of technical object will be available to all.
The maintenance team (Electrical/ Mechanical/Instrumentation) attends the
break down and records the malfunction end time, causes & activities
performed while attending the break down. Here he can also add tasks if
required to be performed afterwards, if some temporary arrangements have
been done.
He creates a maintenance order of Order type PM01 to issue materials/spare
parts if required from their local stores. If the material is not available in their
store a purchase requisition can be made directly from the maintenance order.
In operation list of the maintenance order all operation performed, work center
used and man power hour utilization is recorded.
Break down indicator in notification, will be marked if break down occurs.
External services can also be utilized from maintenance order
Spare parts planning can be done using Bill of materials.
Actual/planned/estimated cost incurred on attending break down will be
summarized with labor & spares cost separately.
Failure analysis can be recorded.

Copyright 2011 JKT

Page 2 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Refer flowcharts below:

1. General Maintenance process (Internal processing)
2. General Maintenance process (External processing both Material &
Service)

o PROCESS FLOW CHARTS

1.1.1 General Maintenance Process (Internal processing)
Create Notification
(Request for maintenance
by plant user/CCR)
-Description of job
-Required Start and
End times of job
-Technical object no.
-Technical findingsObject part, damage
etc. (optional)
-Tasks to perform

Notification
receipt by
Maintenance Dept.

Inspection of
Machine at site by
maint. person
-Enter additional technical
findings and tasks in the
Notification.
-Release the Notification
(Put in process)

Copyright 2011 JKT

Create Maintenance order

for the notification
(by Maintenance planner)
-Description of order
-Technical object details
(transferred from Notification)
-Assign Maintenance work
center (transfers automatically
from the technical object
master record)
Y order
-Plan operations in the
with number of persons
required and work times.
-Plan spare materials with
required quantities
-Assign responsible person

Page 3 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Schedule the order

(for planned start and end times
depending upon the availability of
manpower at the Maint. Work center)
Release the order

X
Issue spare materials from stores

Execute planned
maintenance work at site
Completion (time) confirmation
(of Maintenance order operations)
Inspection of completed
work at site by authorized
person
-Complete the technical
Findings in Notification.
-Complete the tasks

Notification Completion
(by authorized person)

Technical Completion
Of Maintenance order
(by authorized person)

Settlement
of Maintenance order
(by authorized person)

Business completion
of Maintenance order
(by authorized person )

Order closed

Copyright 2011 JKT

Page 4 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

1.1.2 Maintenance order (External processing)

Create Maintenance order

-Description of order
-Technical object details
-Plan external service operation
in
the order. Enter operation
detailsService description or select
service from the standard service
catalog, service quantity & unit,
price and vendor (optional).
-Plan internal operations, if any
-Plan stock spare materials, if any
Schedule the order
Release the order

1.For Non Stock Material

purchase requisition is made
2.Purchase Order is
created.
3.Receipt of material
Execute internal processing
work at site, if any

Purchase requisition for the

external service is created
automatically.
Purchase requisition
receipt by Purchase Dept.
Create Purchase order

Execution of requested
external service by vendor

Create Service Entry sheet

X
Y

Copyright 2011 JKT

Page 5 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Y
X
Completion (time) confirmation
(of Maintenance order operations)

Confirm/Accept Services
(By entering exact quantity
of received services in the
Service Entry sheet by an
authorized person)

Technical Completion
Cost

Invoice receipt

Settlement
Business completion

Bill payment

Notification Processing
Transaction code for creating Maintenance Notification is: IW21
Menu path is : Logistics Plant Maintenance Maintenance Processing
Notification Create
Notification type for are: M2: Malfunction Report
1. Identification of Malfunction by Operation or Maintenance department.
2. A Maintenance Notification is created with type M2 in the system depending on
requirement.
3. Specifying the Description of the Notification as per the nature of maintenance
request or malfunction.
4. Mentioning Object Number and time of request with requisitioner identification in
to the notification screen.
5. The initiator of Notification can enter the Technical findings (Object part, Damage
or cause of damage etc) if he knows the details.
6. Saves the notification.
7. After the job is completed the production person will put the timing of malfunction
end and his identification.
8. Maintenance person has to complete any task assigned to notification and enters
the activities.
9. Lastly, the notification has to be completed by the authorized person.

Copyright 2011 JKT

Page 6 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

PM

Release:

ECC 6.0

Status:

Closed

Order Processing
The transaction code for creating order is IW31.

Menu path : Logistics Plant Maintenance Maintenance Processing

Order Create
Sr
No.
1

Activities

Description

Maintenance
Order Cycle

Permits

Maintenance order is created from the Maintenance

Notification.
Planning operations, Labor resource and materials (if
required) in the maintenance order.
Check Material Availability.
Save Maintenance order and note the Order
Number.
If permits are assigned then those permits has to be
issued by the authorized person.

Physical
Material
Withdrawn
from Main
Stores

If required material is available in main stores

then the material needs to be withdrawn from
the store for executing the maintenance activity.
(The Maintenance Planner will not have
authorization to post Goods issue from main
stores)

Execution of
Maintenance
Work
Completion
Confirmation

Maintenance team will perform the maintenance task

and restore the Object in Ideal condition.
Required material (Spares) will get changed.
Confirms the actual duration and man-hours for the
individual operation.
Records the measurement readings from completion
confirmation screen.
Using the Notification tab button, updates the
catalogs on notification screen.
For other order types the settlement rule is
automatically created, for them rule has to be
checked for its correctness.
After completion of maintenance notification and
entry of tech. Findings, measurement readings the
maintenance order has to be completed technically
to prevent further processing
After completion of all the activities, maintenance
order carries all the maintenance cost; these have to
be settled to the proper cost receiver (Cost Center).
Accounts department will run the settlement of all the
maintenance order periodically to settle the
maintenance orders.

6
7

Completion of
Notification
Creation of
settlement rule

Technical
Completion of
Order

Settlement of
Order

Copyright 2011 JKT

T
Code
IW31

IW32/
IPM2
MIGO

NA

IW41

IW22
IW32

IW32

KO88
/
KO8G

Page 7 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

10

PM

Business
Completion of
Maintenance
Order

Release:

ECC 6.0

Status:

Closed

After settlement of order, the maintenance planner

can close the maintenance order.

IW32

Civil Maintenance: For jobs related to civil maintenance the Plant User will raise
notification of type M1, Maintenance request, for Civil Function locations & also
mentioning the job description required.

The Concerned Civil Planner & Work center will plan for the job in terms of
material & manpower availability.
He will create Order of type PM03 i.e. General maintenance/Request order & get
the material issued.
Remaining all procedures is of same as Break down Maintenance.

1.3

Sr
No
2.1
2.2
2.3
Sr No
3.1
3.2

Special Organizational Considerations

None

Gap Analysis
Gap Identified in proposed solution against Requirements & Expectations
Not applicable
Impact of Requirement
Not applicable
Solution Proposed
Not applicable
Topics
Changes Management Issues
Not Applicable.
Description of Improvements
1. Online information will be available for breakdown and current status of a
technical object.
2. Effective and clear communication of Break down by end user.

Copyright 2011 JKT

Page 8 of 9

Business Blue Print- Business Process- Plant

Maintenance
File Name:
Responsibility:

Sr
No
4.1
4.2

ECC 6.0

Status:

Closed

3. All record related to technical objects are available at any time for analysis and
decision-making.
4. No separate paper work required to maintain equipment history
Topics
Interface / Enhancements considerations
Not Applicable
Reporting considerations
S
No
1

4.3

PM

Release:

Reports

T Code

Breakdown report

MCI7, IW29,
IW39, IW30,
IW40
IW49
IP19, IP24
MCI8
IW67
IE03
MCI5, IW69
MCJB
MCJC

2
Order operations report
3
Preventive maintenance report
4
Maintenance cost report
5
Maintenance report logbook
6
Equipment history card
7
Defect List
8
MTTR/MTBF Equipment
9
MTTR/MTBF Functional Location
Authorization considerations
As per organizational needs, not finalized yet. Authorization matrix is being prepared
separately.

Business Process Signoff

Module

Plant Maintenance
Process
Sub Process /
No

Breakdown Maintenance
Breakdown Maintenance & Civil Maintenance

Description

Breakdown Maintenance & Civil Maintenance

Copyright 2011 JKT

JK_BBP_PM_BP_050
0

Page 9 of 9