Behavior of Performance Based Plan in SAP Plant Maintenance

Overview:
In SAP Plant Maintenance, Preventive Maintenance can be done in many ways.

Time Based Maintenance

Performance Based Maintenance

Time or Performance Based Maintenance (whichever comes first)

Time based Maintenance will work based on Normal Daily Calendar or Plant Factory Calendar or
Maintenance Department Factory Calendar. Whatever the technique, system will calculate exact no.
of days mentioned in Cycle Frequency of Maintenance Plan. Here, scheduling will schedule & plan the
call objects for the whole Scheduling period mentioned in Maintenance plan.
But Performance based plan works in other way. Performance based plan works based on the Running
Hours. KM, etc., as Measuring points for measuring the Performance of the equipment. In this case,
system plan date will keep on gets changed based on daily usage of Equipment. It counts only
Performance of the equipment, so plan date cant be static.
Recently, there is a thread which talks about different scenario & different queries by the Author.
Single cycle count scheduling
To answer his questions as well as to make this process understandable for everyone, this document
has been created.
Performance Based Plan:
Master Data:
All Master Data (viz., Equipment, Measuring Point, Task List, Maintenance Plan) have been created.
As Measuring Point & Maintenance Plan have more importance in scheduling, those screen shots have
been posted below.
Measuring Point:
Measuring Point has been created for KM with Annual Estimate as 300. Here, Annual Estimate has
been taken as half of the Cycle Frequency for which Maintenance Order should be created. In this
example, Maintenance plan call frequency is 564 KM. (All data have been copied from that reference
thread).
Maintenance Plan:
Maintenance Plan has been created with Cycle Frequency as 564 KM, Call Horizon as 100 %,
Scheduling Period as 2 years, Shift Factor for Late Completion & Early Completion as 100 % and Start
of Cycle reading as Zero (0).
Process Flow:
Before updating the Measurement document for KM Measuring point, its not possible to schedule the
orders in IP10. It will provide the Information message as No Counter Reading found & there
wont be any planned calls generated.
So, just create the variant in IP30 (Deadline Monitoring) program with that Maintenance plan &
schedule background job for that variant in SM36.
1st Measurement Document:
Measurement document has been created with KM reading as 123.

1st Scheduling: through IP10 / IP30 (In IP30, mention the Interval for Call Objects as 7 days)
Both calls are in ON HOLD status as Measurement reading doesnt match the Cycle frequency value
of Maintenance plan.
2nd Measurement document:
Measurement document has been created with KM reading as 450.

2nd Scheduling: through IP10 / IP30 (In IP30, mention the Interval for Call Objects as 7 days)
Both calls are in ON HOLD status as Measurement reading doesnt match the Cycle frequency value
of Maintenance plan. But Call dates are different when compared to 1st Scheduling.

3rd Measurement Document:

Measurement document has been created with KM reading as 580.
Now 1st call object has been called as Current KM Counter reading (580) crosses Maintenance plan
cycle frequency (564).

3rd Scheduling:
Scheduling has been done which has generated the Order for 564 KM. As KM reading crosses the
Cycle frequency, Call status will be as NEW START SAVE TO CALL.

Measurement Document at PM Order TECO:

Order generated on 564 KM reading has been executed & after finishing all the operations, PM Order
TECO should be done. While doing PM Order TECO, there is an option to create Measurement
Documents. This will get updated in IP10 scheduling against corresponding call object.
Here, Measurement document has been created say, for KM reading as 640. Here, Scenario is that
Preventive Maintenance has been done during the run of the equipment. Because of Preventive
Maintenance, there is no stoppage in usage of that Equipment. So, Initial reading (580) & Completion
reading (640) are different.
In some cases, Initial & Completion reading will be same.

4th Scheduling:
This is after creating the Measurement document while doing PM Order TECO. In below screen shot,
Completion Counter Reading for 1st Call object has been updated.
Based on Completion Reading at Previous Call Object (1st Call Object), next call object (2nd Call
object) Planned counter reading has been changed.
As per the Master data, Cycle Frequency is 564. So, 2nd Call object should have been generated as
1128. But in below screen shot, Next planned Counter reading is showing as 1204 (640 + 564).
To make system behave this lies with Shift factor mentioned in Maintenance Plan. In Maintenance
plan, it has been mentioned as Shift factor for late completion as well as for early completion as 100
%. So, Next call object Planned reading is getting shifted 100 %.

If there should not be any shift in this Planned Counter Reading for Subsequent call objects, then Shift
Factor for Early or Late completion % should not be maintained.
Here Annual Estimate has been Maintained with some unrealistic value as 300 KM. So by maintaining
some small value in Annual Estimate (approx half of the Cycle frequency), system will only consider
the Measurement document reading i.e., Maintenance will be purely on Performance based.
1. BAIJU KUMARJune 18, 2014 at 2:09 pm
Very good document..Well done..Nice obseravtion..
like (0)

2. Akhilesh SinghJune 19, 2014 at 7:10 am

Hi Maheswaran,
Thanks for sharing to such kind of Observation.
But, If maintain Tolerance (+ or -) range for the same condition and TECO have covered in this tolerances, there
would not be effect in planned cycle.In case TECO beyond from tolerance range then planned cycle would be shift
according to shift factor.
like (0)
1. Maheswaran KD . Post authorJune 19, 2014 at 11:03 am

Hi Akhilesh, Thanks for your feedback & observations. Yes, in my screen shot, I have not maintained the tolerance,
so its shifting 100%. If you maintain some Tolerance (+/-), those will be considered while shifting the counter value.
like (0)
3. Carlos Eduardo AraujoOctober 22, 2014 at 4:06 am

This functionality is a very useful plant maintenance part. This post makes it easy. So, users have a good example
about how to do it.
like (0)
4. Nikhil BengeriApril 6, 2015 at 10:35 am

Hi Maheshwaran,
Thanks for sharing this. A bible for Performance Based Maint.
I wanted to ask, you have not maintained anything in Counter Over Rdg. What would have happend had you
maintained say (500), then, would the new plan be generated??
My ques is whats the role of Counter Over Rdg??
like (0)
5. swapnil rajaneMay 18, 2015 at 10:21 am

Dear Sir,
Thanks for sharing the documents.Its really very very important to understand the concept and the system behavior
as shown by you for preventive maintenance.
Regards.
Swapnil
like (0)

6. PS RAugust 26, 2016 at 3:06 am

Hi Sir,
Its really very useful document

Regards,