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SAP Business Blueprint

Plant Maintenance

SAP Business Blue Print Document Plant Maintenance

Disclaimer
The information contained in this document is to be treated as confidential. No part of this document, wholly or in part
may be distributed in print or as a soft copy as it may contain information which could be the sole proprietary
knowledge of AAHG.

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Sign off sheet


Name Job Title Signature
Mr.Srinivasulu Dud-
Manager-ERP
du

Mr. Santosh Koshy GM - AAA

Maintenance Engi-
Mr. Nirav Desai
neer - API

Maintenance Engi-
Mr. Pradeep
neer - AGT

Maintenance Engi-
Mr. Mohammad
neer - EGC
AAHG Group
Operations Manager
Mr. Husam
– EESF

Name Job Title Signature


Mr. Senthil Kumar
Project Manager
Gandhi
CSC
Mr. Raj Kumar SAP PM Consultant

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1 Document Control ......................................................................................................................................... 6

2 Acronyms....................................................................................................................................................... 7

3 Flow chart key ............................................................................................................................................... 8

4 Introduction................................................................................................................................................... 9

4.1 Executive Summary – AAHG .................................................................................................................. 9

4.2 High level overview of the SAP Plant Maintenance Module ...................................................... 10
Organization Structure ............................................................................................................................... 11
4.2.1.1 Maintenance Plant ............................................................................................................................. 11
4.2.1.2 Planning Plant .................................................................................................................................... 12
4.2.1.3 Planner Group .................................................................................................................................... 13
Master Data ................................................................................................................................................ 13
4.2.2.1 Functional Location ............................................................................................................................ 13
4.2.2.2 Equipment.......................................................................................................................................... 15
4.2.2.3 Bill of Material.................................................................................................................................... 16
4.2.2.4 Measuring Point and Counters .......................................................................................................... 18
4.2.2.5 Task List .............................................................................................................................................. 19
4.2.2.6 Work Center ....................................................................................................................................... 21
Maintenance Process.................................................................................................................................. 21
Preventive Maintenance............................................................................................................................. 25

5 Summary of Business Processes....................................................................................................................30

6 Compiled Business Processes ........................................................................................................................31

6.1 AAHG_PM_001 – Phase In Process ................................................................................................... 31


As-Is Process ............................................................................................................................................... 31
Process Overview........................................................................................................................................ 31
To-Be process ............................................................................................................................................. 31
Business Situation ....................................................................................................................................... 32
Scope .......................................................................................................................................................... 32
8Special Organization Considerations ........................................................................................................ 33
Forms .......................................................................................................................................................... 33
Reports ....................................................................................................................................................... 33
Conversions ................................................................................................................................................ 33
Functional Gaps / Enhancements / Approaches to Functional Deficit ................................................... 33
Workflows .............................................................................................................................................. 33

6.2 AAHG_PM_002 – Phase Out Process ................................................................................................ 34


As-Is Process ............................................................................................................................................... 34
Process Overview........................................................................................................................................ 34
To-Be process ............................................................................................................................................. 34
Business Situation ....................................................................................................................................... 35
Scope .......................................................................................................................................................... 35
8Special Organization Considerations ........................................................................................................ 35
Forms .......................................................................................................................................................... 35

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Reports ....................................................................................................................................................... 35
Conversions ................................................................................................................................................ 36
Functional Gaps / Enhancements / Approaches to Functional Deficit ................................................... 36
Workflows .............................................................................................................................................. 36

6.3 AAHG_PM_003 – Maintenance process ............................................................................................ 37


As-Is Process ............................................................................................................................................... 37
Process Overview........................................................................................................................................ 37
To-Be process ............................................................................................................................................. 37
Business Situation ....................................................................................................................................... 38
Scope .......................................................................................................................................................... 38
8Special Organization Considerations ........................................................................................................ 39
Forms .......................................................................................................................................................... 39
Reports ....................................................................................................................................................... 39
Conversions ................................................................................................................................................ 39
Functional Gaps / Enhancements / Approaches to Functional Deficit ................................................... 39
Workflows .............................................................................................................................................. 39

6.4 AAHG_PM_004 – Refurbishment Process........................................................................................ 40


As-Is Process ............................................................................................................................................... 40
Process Overview........................................................................................................................................ 40
To-Be process ............................................................................................................................................. 40
Business Situation ....................................................................................................................................... 41
Scope .......................................................................................................................................................... 41
8Special Organization Considerations ........................................................................................................ 42
Forms .......................................................................................................................................................... 42
Reports ....................................................................................................................................................... 42
Conversions ................................................................................................................................................ 42
Functional Gaps / Enhancements / Approaches to Functional Deficit ................................................... 42
Workflows .............................................................................................................................................. 42

6.5 AAHG_PM_005 – Preventive Maintenance Process ..................................................................... 43


As-Is Process ............................................................................................................................................... 43
Process Overview........................................................................................................................................ 43
To-Be process ............................................................................................................................................. 43
Business Situation ....................................................................................................................................... 44
Scope .......................................................................................................................................................... 45
8Special Organization Considerations ........................................................................................................ 45
Forms .......................................................................................................................................................... 45
Reports ....................................................................................................................................................... 45
Conversions ................................................................................................................................................ 45
Functional Gaps / Enhancements / Approaches to Functional Deficit ................................................... 45
Workflows .............................................................................................................................................. 46

7 Solution Design .............................................................................................................................................47

7.1 Organization Structure ........................................................................................................................... 47


7.1.1.1 Maintenance planning Plant .................................................................................................... 47
7.1.1.2 Assign Maintenance Planning Plant to Maintenance plant ........................................... 47

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7.1.1.3 Define Planner Groups .............................................................................................................. 48


7.1.1.4 Define Notification Types ......................................................................................................... 48
7.1.1.5 Configure Order Types .............................................................................................................. 48
7.1.1.6 Define Maintenance Activity Types ....................................................................................... 49

8 Gaps .............................................................................................................................................................49

9 Enhancements ..............................................................................................................................................49

10 Annexure -1 : Layouts ...................................................................................................................................49

11 Annexure -3 : Custom Reports ......................................................................................................................50

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1 Document Control

Ver-
Date Author Change Log Approved By
sion
4 April Senthil Kumar First version of Blueprint
1.0
2016 Gandhi

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2 Acronyms

Acronym

ECC Enterprise Central Component


FI Finance
CO Controlling
MM Materials Management
SD Sales and Distribution
PP Production Planning and Control
QM Quality Management
IM Inventory Management
MRP Material Requirement Planning
PR Purchase Requisition
RFQ Request for Quotation (Enquiry)
PO Purchase Order
PIR Purchase Info Record
GR Goods Receipt
GI Goods Issue
TP Transfer Posting
CBP Consumption Based Planning

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3 Flow chart key

Process

Reference
Process

Business
activity/
Event

Document

Exception path

Normal path

Diagram
Connecti
on

Process
decision

Manual
activity

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4 Introduction

This document summarizes the findings of the Computer Sciences Corporation (hereinafter re-
ferred to as CSC) consulting team, which conducted requirement analysis of Al Ahli Holding
Group (hereinafter referred to as AAHG Group) for the SAP ECC system. The information was
gathered through workshops and discussions conducted at the AAHG Project Office with the
managers, key users, as well as reviews of business processes and business procedures fur-
nished by AAHG team after due consultations.

The immediate purpose of the analysis is to prepare to move forward rapidly with the imple-
mentation of AAHG’s SAP ECC system. At the conclusion of the blueprint, CSC Consultants will
determine the SAP functionality required to run the AAHG Group business.

The Blueprint and its associated appendices present a summarized perspective of all functional
business processes that will be implemented. As such, the Blueprint document will serve from
this point forward the dual role of both official project scope as well as system acceptance cri-
teria.

The Blueprint reiterates the SAP ECC organizational structures that have been identified and
will serve as the basis for the initial configuration activities. The CSC team believes that SAP
ECC can accurately model AAHG Group organizational requirements.

The information gathered and documented in the Blueprint is sufficient for the team to go for-
ward into the Realization phase. However, it is critical that both the CSC and AAHG Group
teams agree on the scope of the project as presented in this document. Acceptance by both
teams is required to move the project into the next phase.

This section gives an overview of the solution that will be provided for the Plant Maintenance.
A number of integrated processes have been identified that cover the way Plant Maintenance
will be carried out in AAHG group once the new system is implemented.

The SAP solution will have the Enterprise Areas of Finance, Controlling, Materials Man-
agement, Sales and Distribution, Production Planning & Control, Quality, Project sys-
tems and Human Capital Management. This document outlines and then details the sec-
tions from the process group which relates to AAHG Group Plant Maintenance Area.

The Plant Maintenance module can be divided into the following key Process Groups:

 Master data
 Maintenance Process
 Preventive Maintenance Process

4.1 Executive Summary – AAHG

Al Ahli Holding Group is a multi-diversified international conglomerate with over four decades
of successfully dealing with business activities ranging from real estate to turnkey construc-
tion, engineering and infrastructure, retail and trading, technology and logistics, lifestyle and
fitness, entertainment, hospitality and innovative developments.

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With great passion and a very active portfolio in the entertainment industry, AAHG operates
innovative and ground-breaking projects in the UAE.

AAHG, amongst its portfolio

 Owns Dubai Outlet Mall, which is the first outlet mall concept in the Middle East.
 Constructed major landmarks in the Eastern region of UAE.
 Holds the exclusive largest franchise rights to US-based Gold’s Gym International in the
Middle East and Africa.
 Owns Al Ahli Plastics, one of Middle East’s largest plastic manufacturing companies.
 Holds licenses to publish Marvel, Warner Bros., DC Comics and Sanrio comics and activ-
ity inks.
 Owns Comicave, the world’s largest comic and superhero collectibles destination store
at Dubai Outlet Mall.
 Launched Singapore-based companies with Comicave Studios, manufacturer of high-
end collectibles and toys.
 Owns Universal Events to host and organize comic and pop-culture based events and
conventions.
 Recently acquired Audience, one of the world’s largest publishers of multi-channel so-
cial and digital content to create new direct-to-consumer media services.
 Launched 117 Live, an events company dedicated to hosting international live events
and offering events-based ancillary services.

The company announced to build a Fox-branded theme park and resort in Dubai and has stra-
tegic alliances with Fox Studios, Marvel-Disney, Sony Pictures Warner Bros and other leading
Hollywood studios across its multi-entertainment based platforms.

With around 9,000 employees, AAHG is headquartered in the UAE, with representative offices
across 20 countries globally.

AL AHLI group proposes to implement SAP in 14 of its companies – 7 companies as part of


wave 1 and 7 companies as part of wave 2.

4.2 High level overview of the SAP Plant Maintenance Module

Plant Maintenance Module of SAP communicates with other modules in the SAP System to en-
sure a constant flow of information relates to Machineries and Assets. For example, it works
side by side with the following modules like Financial Accounting (FI), Controlling (CO), Materi-
als Management (MM), Project Systems (PS) and Sales & distribution (SD)

The Plant Maintenance module will discuss the following:

1. Master Data Objects


a. Functional location
b. Work center
c. Equipment
d. Equipment Bill of Material
e. Measuring Point

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f. Task list
g. Catalogs
2. Business Process
a. Breakdown Maintenance
b. Preventive Maintenance
c. Refurbishment Process
d. Calibration Maintenance
e. Equipment mobilization and return process
f. Measurement document for Fuel and counters

Organization Structure

The Organizational Structure in MM consists of following Organizational Levels

 Maintenance Plant

 Planning Plant

4.2.1.1 Maintenance Plant


Plant is an organizational unit under company code serving to subdivide an enterprise ac-
cording to production, procurement, maintenance, and materials planning aspects. A plant
is represented by a unique 4-digit alpha-numeric for a specific client.
The maintenance plants for a technical object is the plant at which Equipment is installed and
where main work centers exist
Following Maintenance Plants will be defined in the system:

Company Maintenance
Company Country Plant description
code Plant
Al Ahli Holding Group
Al Ahli Holding Group (AAHG) UAE 1000 1000
(AAHG)
Al Ahli Plastics Indus-
Al Ahli Plastics Industries (API) UAE 1100 1100
tries (API)
Emirates General Con-
Emirates General Contracting (EGC) UAE 1200 1200
tracting (EGC)
Al Ahli Aluminium
Al Ahli Aluminium (AAA) UAE 1300 1300
(AAA)
Emirates Engineering
Emirates Engineering Services &
UAE 1400 1400 Services & Factories
Factories (EESF)
(EESF)
Gulf Spring Contacting
Gulf Spring Contacting (GSC) UAE 1500 1500
(GSC)
Al Ahli General
Al Ahli General Transport (AGT) UAE 1600 1600
Transport (AGT)
Comicave Studios - Sin-
Comicave Studios - Singapore Singapore 1700 1700
gapore

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Comicave Toys & Games Trading – Comicave Toys &


UAE 1800 1800
Dubai Games Trading –Dubai
Al Ahli Publishing and Distribution Al Ahli Publishing and
UAE 1900 1900
(APD) Distribution (APD)
Little Manila UAE 2000 2000 Little Manila
Dubai Outlet Mall
Dubai Outlet Mall (DOM) UAE 2100 2100
(DOM)
Gold’s Gym Interna-
Gold’s Gym International (GGI) UAE 2200 2200
tional (GGI)
Rethink Leisure Enter-
Rethink Leisure Entertainment USA 2300 2300
tainment
Universal Events UAE 2400 2400 Universal Events

4.2.1.2 Planning Plant


The maintenance planning plant for a technical object is the plant in which the mainte-
nance tasks for the object are planned and prepared. Maintenance planner groups work at
the maintenance planning plant to plan and prepare the maintenance tasks for the plants
that are assigned to the maintenance planning plant. The following activities are performed
at the maintenance planning plant:
Definition of task lists
Material planning based on bills of material in task lists and orders
Management and scheduling of maintenance plans
Creation of maintenance notifications

Maintenance
Planning Plant Description
Plant
1000 1000 Al Ahli Holding Group (AAHG)
1100 1100 Al Ahli Plastics Industries (API)

1200 1200 Emirates General Contracting (EGC)

1300 1300 Al Ahli Aluminium (AAA)

1400 1400 Emirates Engineering Services & Factories (EESF)

1500 1500 Gulf Spring Contacting (GSC)


1600 1600 Al Ahli General Transport (AGT)

1700 1700 Comicave Studios - Singapore

1800 1800 Comicave Toys & Games Trading –Dubai

1900 1900 Al Ahli Publishing and Distribution (APD)

2000 2000 Little Manila


2100 2100 Dubai Outlet Mall (DOM)

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2200 2200 Gold’s Gym International (GGI)


2300 2300 Rethink Leisure Entertainment
2400 2400 Universal Events

4.2.1.3 Planner Group


Group of employees responsible for the planning and processing of maintenance tasks in a
particular plant are known as Planner Group. Planner groups will be created with respect to
a Planning Plant.
Every piece of equipment and functional location can be allocated to a maintenance plan-
ning group.
Maintenance planning groups can also be used for evaluation purposes.

Master Data

Master Data is a single source of basic business data used across multiple systems, applica-
tions, and/or processes.

Information that is key to the operations of a business. It is the primary focus of


the Information Technology (IT) discipline of Master Data Management (MDM), and can include
reference data. This key business information may include data about customers, products,
employees, materials, vendors.

Below are the list of master data which are important in PM:

– Functional Location
– Equipment Master
– Measuring Point
– Bill of Material
– Catalogs
– Work center
– Task List

4.2.2.1 Functional Location

Functional Location is an organizational unit within Logistics that structures the maintenance
objects of a company according to functional, process-oriented or spatial criteria. A functional
location represents the place at which a maintenance task is to be performed.

Each functional location 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.

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

Use:

A functional location represents system area at which an object can be installed. The objects
that can be installed at functional locations are called pieces of equipment in the System.

Technical data can be collected and evaluated over long periods of time for the individual areas
of the system or operational structure.

The costs of maintenance tasks can be monitored for the individual areas of your system or
operational structure.

You can perform analyses on the influence of usage conditions on the damage susceptibility of
the pieces of equipment installed.

To determine the generic structure of the location number and make the hierarchy levels with-
in the location structure visible in the location number separate structure indicators shall be
created for manufacturing and site functional locations. The Structure indicators shall be al-
phanumeric structures wherein the edit mask is represented as N (number), A (letter), & X
(both).

Figure 1 : Functional Location Structure Indicator

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The coding of the functional location will be Alpha Numeric with separators and based on the
coding logic of the functional location the system will automatically derive the superior func-
tional location. However the user has the option to change the same.

4.2.2.2 Equipment

Equipment is an individual, physical object that is to be maintained as an autonomous unit.


You can manage all types of device as pieces of equipment (for example: production utilities,
production resources/tools, buildings, PCs, transportation utilities, test equipment).

Use:

Managing 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.

The costs of maintenance tasks can be monitored for the object.

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Records of usage times at functional locations for the object.

Equipment shall be broadly classified in to following categories:

M – Technical system

P – Production resource tools

O- Office and IT equipment

The Equipment number shall be generated internally based on these equipment categories.

Equipment details shall be captured in the system using equipment master data. The data cap-
tured in the equipment master shall be as following:

General Data – Manufacturer, Manufacturer part no, serial no, year of manufacturing, Acquisi-
tion data.

Location Data – Maintenance plant.

Organization Data – Company code, asset, cost center, Planning Plant, Planner group, Mainte-
nance Work center.

Structural Data – Hierarchy, functional location.

Vehicle information – Data related to Vehicles

Measuring points can be attached in the Equipment Master.

Asset number maintained for the Asset master in the FI module can be linked to the Equip-
ment master.

Material number can be linked to the Equipment master as the construction type for indirect
linking for Bill of material purpose

4.2.2.3 Bill of Material


A maintenance 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 indi-
vidual components (material numbers) 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.

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Use:

Maintenance BOMs are primarily used for the following purposes:

Structure description:

Maintenance BOM describes the structure of a technical object or material. Using maintenance
BOMs you can specify exactly where maintenance tasks are to be performed on a technical ob-
ject.

Assignment of spare parts:

A maintenance BOM is used in plant maintenance to assign spares for a technical object or
material.

The use of maintenance BOMs is advantageous for material planning, because it is possible to
perform material planning when creating a maintenance task list and maintenance order. BOM
can be created for individual technical object like functional location, Equipment and material
(Maintenance assembly).

A BOM can be linked to a technical object in two ways:

Direct allocation:

Direct allocation is performed by directly linking one or more master records to a BOM, without
inserting a material master record. If all the technical objects are identical in terms of struc-
ture, the BOM items are valid for all the allocated technical objects. If individual materials or
assemblies are only valid for certain objects, a joint BOM can still be used. In this case, the
object-specific differences can be documented using variant items.

Indirect allocation:

Master records for technical objects can be indirectly allocated to a BOM if the master records
are linked to a material master record which contains its own material BOM via the field Con-
struction Type. This is the case when a company has several identical technical objects
grouped under one material number.

In the BOM, the components can be differentiated based on the following item categories for
planning purpose:

L – Stock item

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This item category applies to components which are kept as stock. Any components entered
with this category in the BOM must have a valid master record in the system. When you use
this item category, stock item components are automatically reserved for the maintenance or-
der.

N – Non-stock item

This item category is used for components which are not kept in stock, if they are used in a bill
of material (BOM). Non-stock items can be entered in the BOM with or without a master rec-
ord. To enter a non-stock item without a master record, you must simply enter a descriptive
text. When you use this item category, the system automatically creates a purchase requisi-
tion for these components, when they are used for maintenance purposes. This leads to order-
specific materials procurement via the purchasing department

4.2.2.4 Measuring Point and Counters


Measuring point:

Measuring points describes the physical and/or logical locations at which conditions described,
(for example, the coolant temperature in a nuclear power station after the coolant has left the
pressure vessel, or the number of revolutions at a rotor shaft of a wind-driven power plant).

Measuring points are located on technical objects, in other words, on pieces of equipment or
functional locations. For example, in a storeroom for fruit, a certain room temperature has to
be created and maintained. The temperature is kept constant by a regulator, and is also
checked regularly by a measuring device. The storeroom is represented in the system as func-
tional location. The temperature measuring device is then created as measuring point for this
functional location.

Counter:

Tools that you use to represent the wear and tear of an object, consumption, or the reduction
of an object’s useful life are described as counters.

Use:

Measurement readings are taken at measuring points in particular measurement units at par-
ticular intervals. For example, the temperature in degrees Celsius of the coolant in the coolant
pipe that leaves the pressure vessel at the nuclear power station, or the number of revolutions
per minute at the rotor shaft of the wind-driven power plant.

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Measurement readings describe a condition at a measuring point at a particular point in time,


and represent the transaction data for measuring points in the SAP System. They are docu-
mented in the form of measurement documents. In many cases, there may be an optimum
value for a particular measuring point to which the device concerned is calibrated. You can
specify this measurement reading as a target value for the measuring point.

Measurement readings can be recorded in three different forms:

 Quantitative

 Qualitative

 Combination of both

Measuring points shall be created for functional locations as well as equipment.

Measuring points shall be following one category - M for creating internal number ranges.

 Each measuring point will have a measuring position, which will be unique for every
measuring point for checking the duplications.

 Measurement ranges can be assigned to individual measuring points with lower range
and upper range limit.

 If the measuring point is quantitative, then a characteristic can be linked to the meas-
uring point with the unit of measurement.

In the case of counter-based maintenance, maintenance activities can be performed when the
counter of the technical object has reached a particular counter reading, for example, every
100 operating hours. Counter-based maintenance can be employed for technical systems with-
in the process.

A measurement document will be created after recording the measurement readings for a
measuring point. This measurement document number is unique and shall follow internal
numbering for generation.

4.2.2.5 Task List


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. Many manufacturers deliver their technical
objects together with maintenance task lists; these task lists are, however, frequently created
within the company itself.

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Use:

Task lists help to reduce the maintenance effort when standardized work sequences change,
for example as a result of new legal regulations. You must carry out the changes at exactly
one place in the corresponding maintenance task list. All maintenance orders and maintenance
items that refer to the maintenance task list automatically receive the actual status of the
work sequences.

Can use maintenance task lists in the following areas of Plant Maintenance:

Planned maintenance

Ongoing maintenance

Maintenance task lists contain important information such as the spares and tools required for
the work steps or the time required performing the work.

Task list are distinguished in to three types:

Functional location task list

Equipment task list

General task list

General task list:

General maintenance task lists are task lists that are used for general maintenance tasks. They
do not refer to a specific technical object. Using general maintenance task lists, you can define
and manage sequences of maintenance tasks centrally, and use them for work scheduling.
Within a group, you can create several individual general maintenance task lists. This clearly
identifies each general maintenance task list within the group.

Use:

General maintenance task lists help you to prepare maintenance plans and orders. Further-
more, you can use these task lists to reduce the time spent creating equipment task lists.

Task has the following elements which support in performing maintenance functions:

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An operation specifies the time, work centre and other control information required for the
maintenance task.

Material components

Can assign material required for maintenance task.

Maintenance packages:

The maintenance cycles and packages contain the time or performance condition when
Maintenance must be performed.

4.2.2.6 Work Center


The work center usually represents one person or a department, responsible for ensuring that
the maintenance work in an order is executed by the work centers performing the individual
operations.

Use:

Work centers are used in task list operations and maintenance orders.

Formulas and Activity type are entered in the work center, so that the costs of an operation
can be calculated. A work center is also assigned to a cost center.

A work center shall be created for a plant and is identified by a key. The work center category,
which defines in customizing the work center, determines which data can be maintained in the
work center. The work center master shall be created based on category ‘Labour’. Description
for Work Center would be position wise, as mentioned in below table.

The usage of work center shall be maintained as ‘All task list type’.

Maintenance Process

An overview of the basic process flows specific to different types of maintenance is given be-
low. These have been discussed in detail in the later paragraphs.

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Notification:

When the Station Supervisor observes any malfunction in the Equipment, he can inform the
Workshop Maintenance Supervisor.

The Maintenance Supervisor can initiate the Maintenance work by creating a Notification. The
following

Notification types can be used:


 M1 – Maintenance Request – Can be used for the jobs of which the Operator foresee to
perform in the Equipment by the Maintenance person

 M2 – Malfunction Report – Can be used for reporting the malfunctions in the Equipment
or functional location

 M3 – Activity Report – Can be used for jobs of which Maintenance Department wishes
to execute in Operation area

The Maintenance Supervisor can record the following details in the notification:
 Coding (Predefined Damage/Cause of damage code)

 Brief as well as long description of the problem / Defect

 Planner group who plans for this Maintenance activity

 Work center who are responsible to carry out the Maintenance activity

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 Name of the person who reports this notification

 Required start and end date and time for carrying out the job

As soon as the notification is created, the system status of the notification can be displayed as
‘Outstanding Notification’.

The Maintenance person can acknowledge the notification by converting the status to ‘Put in
Process’.

If the Maintenance person wishes to carry out the activity in the later date or wishes to com-
bine with future shut down or if the spares are not available at present or if the clearance is
not available, he can convert the status of the notification to ‘Postponed’. The reason for Post-
poning can be written in the Test field.

The Maintenance Department can convert the Notification to Order. The system status of the
notification gets converted to ‘Notification in Process’ and ‘Order assigned’.

After successful completion of the activity, the Maintenance person can record the details of
the activities and findings in the Notification along with details of activity start and end date &
time.

Provision will be given for the Maintenance Department to describe the Malfunction/damage,
Object part, Cause of damage, Activities that were done to the Equipment, with the help of se-
lectable predefined texts (Catalog) to maintain the consistency in reporting and also to do the
evaluation.

Damage, Cause of damage codes shall be created and catalogued to facilitate easy data input
and detailed analysis and reporting requirements of the problems. Maintenance Supervisor af-
ter confirming the satisfactory performance of the activity can close the notification. The
Equipment history gets updated in the information system.

Maintenance Order:

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Maintenance Order

Operation Done In
house. Activity cost will Requirement of stock Requirement of non Requirement of service
be captured material stock material from external agency

Creation of Creation of
Confirmation of Creation of
purchase purchase
labour hours reservation
requisition requisition

Figure 2 : Maintenance Order Cost Collection Element

The Maintenance supervisor can initiate the Maintenance work by creating a Notification/Order.

The Maintenance person can convert the Notification into Order for attaching the required Ma-
terials and Manpower and for release the Order for the Cost center booking. The Maintenance
person can also directly create the Order.

Many Notifications can be assigned to a single Maintenance order. The history will be made
available only for the Equipment entered in the header of the Order.

The following types of Orders are proposed and can be used in the system:

PM01-Corrective Maintenance order - Can be used for planned routine activities

PM02- Breakdown Order - Can be used for Breakdown activities

PM03- Preventive Maintenance order - Can be used for Planned activities / Preventive activi-
ties

PM04-Refurbishment Order – Can be used for reconditioning of material or Equipment

PM05- Calibration Order – Can be used for calibration of equipment

While creating Order, the Maintenance person can record the following details:
 The activity description
 Work center who are responsible to carry out the Maintenance activity
 Planner group who plans for this Maintenance activity
 Activity type
 Activity planned Start date and Finish date
 Related Technical objects (Functional location and Equipment)

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 Task list to be performed


 Required man-power and man-hour duration
 Required Materials with quantity.
 Relevant Cost center

Reservation number gets automatically generated for the Order with Materials.

A purchase requisition gets created if the material belongs to non-stock within the component
list of the Order.

The Maintenance Department can withdraw the required material from the Stores based on the
reservation created automatically from the Order.

Maintenance Department can carry out the job and upon completion of the work; user can en-
ter the time taken for each operation.

The Maintenance person can enter the completion confirmation in the system by entering the
start/end time, he can also record the Tasks carried out. They can enter the overall technical
confirmation and business completion. After the business completion, no movements can be
made possible against the Order.

Based on the Order status and the Confirmations, the progress of the Maintenance Order can
be monitored. The Equipment history gets updated in the information system.

Preventive Maintenance

Ensuring a high availability of objects in the long term is an important part of Plant Mainte-
nance. Planned maintenance is used to avoid system breakdowns or the breakdown of other
objects, which - in addition to the repair costs – often result in much higher costs subsequently
owing to production breakdown.

There are many benefits in using planned maintenance within a company. It is the generic
term for inspections, preventive maintenance and planned repairs, for which the time and
scope of the work can be planned in advance.

The planned maintenance need to include the considerations like;

 Manufacturer recommendations

 Prevailing Working conditions

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 Legislative requirements

 Environmental stipulations etc.

The Maintenance Planning component is integrated with the following components and sub-
components:

 Maintenance task lists

 Maintenance Items

 Maintenance Plans

We can use maintenance planning to describe the dates and scope of plan able maintenance
and inspection activities at technical objects. Can ensure that the technical objects are main-
tained on time and thereby function optimally. The system generates maintenance call objects
during the scheduling process. The maintenance planning can be done on

 Functional Location (which may comprise piece/s of equipment)

 Equipment (which operates independently of other equipment)

Maintenance Planning:

Maintenance Plan is a means used to describe the dates and scope of the maintenance and in-
spection activities that are to be carried out at technical objects (on Equipment or on Function-
al location).

A Maintenance Plan can be:

 Time based (Weekly, Fortnightly, and Monthly etc.)

 Performance based (Run hour based, kilometres etc). For such activity based mainte-
nance plan, a measuring point has to be identified in the maintenance plan, which shall
record the performance at regular intervals. If it is a counter (Like Hours or Litres, we
need to enter the average annual performance i.e. average hours/Litres run in a year)

Maintenance Plans can be classified in to:

 Single cycle Plan

 Strategy Plan

Single cycle Plan: This type of plan can be used for the checks which are to be performed
regularly at a single frequency. For example: If we have only a few checks to be performed

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every week and there are no different checks for other frequencies (say monthly), then single
cycle plan can be used.

Strategy Plan: On the other hand, if we have a few checks to be performed once in a week,
some other checks once in a month and few more checks once in three months and so on,
then we have to use Strategy Plan.

A strategy plan shall have Maintenance strategy. Maintenance strategy is the rule for sequence
of planned maintenance work. The maintenance strategy contains the maintenance packages,
which define how frequently the individual jobs are to be carried out.

For example, one maintenance strategy can have maintenance package in multiples of week
(Weekly, fortnightly etc.). Another maintenance strategy can have maintenance packages in
multiples of running hours (once in every 150 hours, once in every 300 hours, once in every
600 hours etc.).

A Maintenance Plan consists of:

 Maintenance Item(s) – Maintenance Item in turn consists of details of Equipment/FL


with their respective Task list (Check list).

 A maintenance schedule.

Maintenance Item:
A maintenance item describes which preventive maintenance tasks should take place regularly
at a technical object or a group of technical objects. In simple words Maintenance Items link a
task list and Equipment or Functional Location.

Once the Maintenance Item is attached to a maintenance plan, on regular basis as per the
predefined frequency Maintenance orders shall get generated at regular intervals.

You can assign maintenance items to a maintenance plan in the following ways:

 Can create a maintenance plan and create a maintenance item directly in the mainte-
nance plan by entering the required data in the tab Item.

 Can create additional maintenance items in a maintenance plan.

 Can create a maintenance item without assignment and subsequently assign it to a


maintenance plan.

The following rules apply if you assign a maintenance item to a maintenance plan:

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 A maintenance item can only be assigned to one maintenance plan.

 The maintenance item you assign to a strategy plan must have the same maintenance
strategy as the maintenance plan.

 The maintenance item you assign to a strategy plan must have the same maintenance
plan category as the maintenance plan.

Maintenance Plan also stores information on:


Start of the cycle:
If it is a time based maintenance plan, it is the start date from which the system shall calculate
the due dates for next maintenance. If it is a performance/activity based maintenance, it is the
hours from which it shall calculate the next maintenance due.

Scheduling period:
Scheduling period is used to display a preview of the maintenance dates in the queue.
The scheduling period specifies in days, months, or years the actual length of time over which
scheduling will take place. For example, if you want a maintenance plan to be scheduled for
the entire year, so that all the calls are generated for this year, you must enter 365 days or 12
months as the scheduling period.
For example: If we give the scheduling period as 365 days, the system shall create a calendar
indicating various dates on which the different maintenance shall be due for that particular
plan. For a maintenance plan, which is activity based –based on the average run hours per
year, the system calculates the average per day running, then estimates the future dates on
which the various maintenance can fall due and then creates the calendar for the scheduling
period.

Call Horizon:
This parameter decides, the advance intimation period for a scheduled maintenance order. In
simple terms, if a given maintenance is scheduled to be due on a future date (say 1st January,
20016) it is the date on which the maintenance order should get generated on 31st December,
2017 or on 30th etc. so that the Maintenance Engineer shall be in a position to plan in ad-
vance. This ‘Call Horizon’, is to be given in terms of percentage of the smallest frequency of
the maintenance package used in the Maintenance Plan. For example, if in a maintenance plan
with ‘strategy1’ as shown in example, if ‘Call Horizon’ is given as 15%, then the minimum fre-
quency of the package used is 1 week. Then 15% of one week is approximately one day. The
scheduled maintenance order call date will be one day in advance to the scheduled start date.

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Maintenance Plan sort field:


Maintenance Plan sort field is useful in retrieving list of maintenance plans relevant to a given
area. This sort field has been configured as per the following template.
Above all, when a maintenance plan is displayed, ‘schedule overview’ – calendar indicating, the
various maintenance calls falling due in the scheduling period can be seen.

Maintenance Schedule:
Regular generation of maintenance orders as per the maintenance plan has got two steps in-
volved.

Scheduling:
When a maintenance plan is scheduled, the system calculates the due dates for the mainte-
nance tasks that are to be performed for the scheduling period mentioned in the maintenance
plan.

Deadline monitoring:
By doing the deadline monitoring function, the system converts all the maintenance calls, for
which the call horizon has been reached, into maintenance orders. The system also performs a
complete rescheduling of the maintenance plan and ensures that maintenance calls are always
available for the period which you have defined as the scheduling period.

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5 Summary of Business Processes

The below mentioned list of business processes are considered as part of the Implementation scope for
AAA, API, EESF, EGC, GSF and AGT

Major Business Process-


S.No. Description
es
1 AAHG_PM_001 Phase In Process
2 AAHG_PM_002 Phase Out Process
3 AAHG_PM_003 Maintenance Process
4 AAHG_PM_004 Refurbishment Process
5 AAHG_PM_005 Preventive Maintenance Process

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6 Compiled Business Processes

6.1 AAHG_PM_001 – Phase In Process

As-Is Process

 Currently there is no system to maintain Equipment master and phase-in activities in


system
Process Overview

When new machine is purchased, then this process will help maintenance supervisor to have
step wise approach to create relevant equipment master data in system which is required to
map life cycle of the object

To-Be process

Phase In Process

STANDARD DECISION
SAP
Event

PROCESS PROCESS
Start End START END
MANUAL MANUAL
INPUT OPERATION
Finace Dept

Create Asset Information of


Master – asset given to
Finance maintenance
process dept
Manager

Create
Equipment
Master with
reference to
Asset ID
Maintenance Supervisor

Create Class
Create Task List
and
as per the Create a BOM
Characteristics
requirement
for equipments

Create Create a Install


Measuring Point Maintenance Functional
if required Plan Location

Process Steps:

Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

1. Create Equipment M SAP IE01 Maintenance Whenever new equipment


Supervisor is added create a master
record for the same.

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Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

2. Create measure- O SAP IK01 Maintenance Create a measuring point,


ment point/ Supervisor if required for the new
counters equipment.
3. O SAP IA05 Maintenance Create a task list as per
Create task list Supervisor maintenance requirement
to the equipment.
4. M SAP IP41/IP Maintenance
Create mainte- Create a maintenance
nance plan 42 Supervisor plan for scheduling.

5. O SAP IB01 Maintenance Create a list of spares at-


Supervisor tached with the equip-
ment or attach the BOM
Create BOM
which already exists, if
applicable to this equip-
ment type.
6. Create Character- O SAP CT04/CL Maintenance Enter the class & charac-
istics and 02 Supervisor teristics related to the
Class equipment.
7. Install the M SAP IE02 Maintenance
Supervisor Install the equipment in
equipment in
the respective functional
functional loca-
location.
tion

Business Situation

When new equipment is procured which needs maintenance history to be maintained in sys-
tem.

If the equipment is an asset, the asset will be created in Finance module and the Asset num-
ber will be maintained in Equipment master during this process

If the Equipment is automatically created when it is received in warehouse (serial number


management), the maintenance supervisor updates other information based on this process.

Scope

# Company Code Company Name


1 1100 Al Ahli Plastics Industries (API)
2 Emirates General Contracting
1200
(EGC)
3 1300 Al Ahli Aluminium (AAA)
4 Emirates Engineering Services &
1400
Factories (EESF)
5 1500 Gulf Spring Contacting (GSC)

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# Company Code Company Name


6 1600 Al Ahli General Transport (AGT)
8Special Organization Considerations

 None Identified

Forms

 None Identified

Reports

The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.

# Report Name Transaction Code


1 Equipment list IE05

Conversions

# Requirement Description
1 AAHG-PM-CON-001 Functional location
2 AAHG-PM-CON-002 Equipment
3 AAHG-PM-CON-003 Task List
4 AAHG-PM-CON-004 Preventive Maintenance Plan

Functional Gaps / Enhancements / Approaches to Functional Deficit

 None identified

Workflows
 None identified

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6.2 AAHG_PM_002 – Phase Out Process

As-Is Process

 Currently there is no system to maintain Equipment master and phase-out activities in


system
Process Overview

When equipment is being retired, then this process will help maintenance supervisor to have step wise ap-
proach to deactivate equipment in system. This will be done in two phases i.e. scrapped or sold. Updating
the equipment master data with relevant information

To-Be process

Phase Out Process

STANDARD DECISION
SAP
Event

PROCESS PROCESS
Start End START END
MANUAL MANUAL
INPUT OPERATION
Finance Dept

Asset
Retirement
process
Approval
Manager

Set the Equipment


status as
“Inactive”
Maintenance Supervisor

Dismantle Functional Close all the pending Deactivate the Inform Finance
Identify the Location from Order of the maintenance plan of dept to scrap
equipments which Equipment Equipment Equipment the asset
are to scrapped

Process Steps:

Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

1 Set Equipment M SAP IE02 Maintenance


Keep equipment state del-
status for dele- Supervisor
tion flag
tion flag
2 Review and close M SAP IW32 Maintenance Close all outstanding or-
outstanding ders which are available in

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Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual
maintenance or- Supervisor orders.
ders
3 M SAP IP02 Maintenance Keep the plans which are
Set Maintenance
Supervisor available on that equip-
plan inactive
ment in active
4 Archive master M SAP SARA Maintenance
Archive the master data of
data of Equip- Supervisor equipment
ment
Business Situation

When Equipment scrapping request is provided by field unit/production shop floor to the
Maintenance in-charge. Based on their request and approvals from the higher authorities of
maintenance equipment will be scrapped. Then update the equipment master data with
scrapped related information.

Maintenance in-charge will de-activate any maintenance plans, close any Open notifications,
maintenance order, service entry sheet etc.

Once the equipment is sold out then relevant information will be updated in the equipment
master data.
Scope

# Company Code Company Name


1 1100 Al Ahli Plastics Industries (API)
2 Emirates General Contracting
1200
(EGC)
3 1300 Al Ahli Aluminium (AAA)
4 Emirates Engineering Services &
1400
Factories (EESF)
5 1500 Gulf Spring Contacting (GSC)
6 1600 Al Ahli General Transport (AGT)
8Special Organization Considerations

 None Identified

Forms

 None Identified

Reports

The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.

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# Report Name Transaction Code


1 Equipment list IE05

Conversions

 None Identified

Functional Gaps / Enhancements / Approaches to Functional Deficit

 None identified

Workflows
 None identified

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6.3 AAHG_PM_003 – Maintenance process

As-Is Process

 Currently there is no system for maintenance related process for creating the mainte-
nance order
Process Overview

When any machine breakdown occurred due to operational error or machine problem, Produc-
tion/Operation department will inform to the Plant maintenance department. Maintenance de-
partment will identify the identify the faults and attend the breakdown.

To-Be process

Breakdown Maintenance

STANDARD DECISION
SAP
Start End
Event

PROCESS PROCESS
START END
MANUAL MANUAL
INPUT OPERATION

Create
Stake Holder

Inform to Notification- M2
Identify requirement Login access
N maintenance type
of creating exist
dept
notification

Create a
Maintenance System creates
Create M2 Review Maintenance Component Stock
Order Y Y Y reservation
Notification Notification Order – PM01 required..? available..?
required..? number
type
Maintenance User

Close the M2 N N
Notification

Complete the
Update technical System creates
PM01 External
findings in M2 N Y Purchase
Maintenance Service Req..?
Notification requisition
Order
Technician

Execute
the work

Purchase
MM

GRN / SES Goods Issue


Order Process
Process
process

Process Steps:

Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

1 Creation of Noti- M SAP IW21 Maintenance Create a notification for


fication Supervisor the maintenance of the
technical object

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Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

2 Change of Notifi- M SAP IW22 Maintenance Change the notification to


cation Planner keep in process
3 M SAP IW31 Maintenance
Creation of work Create work order for the
Planner
Order respective notification

4 Change of M SAP IW32 Maintenance


Change the order to keep
Maintenance or- Planner
in process
der
5 Withdrawal of M SAP MIGO Stores In-
material for charge Withdrawal of the re-
maintenance Or- quired material for order
der
6 Time confirma- M SAP IW41,I Maintenance
Record the time details of
tion for each op- W42,IW Planner
each operation wise or
eration Individual 48
collectively for all the op-
/collective /over
erations in order.
all profile
7 Technical comple- M SAP IW32 Maintenance Technically complete the
tion Planner order
8 Entry of Technical M SAP IW22 Maintenance Enter the observations
findings Planner which have been found
during maintenance
9 Closing of Notifi- M SAP IW22 Maintenance Close the notification for
cation Planner completeness
1 Run settlement M SAP KO88/K Finance Settlement is done by fi-
0 cycle O8G nance people
1 Business comple- M SAP IW32/C Finance Close the order to indicate
1 tion of Order O99 business completion is
done for the order.

Business Situation
User will create the corrective notification against the abnormality of the technical object.
Based on the observations maintenance supervisor will convert the order to respective notifi-
cation.
Maintenance supervisor will assign the spares in the order for executing the activities of the
order

If material has to procure from externally he will create the PR for required material in the or-
der
If it is external service the service related information will be updated in the order
Scope

# Company Code Company Name

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# Company Code Company Name


1 1100 Al Ahli Plastics Industries (API)
2 Emirates General Contracting
1200
(EGC)
3 1300 Al Ahli Aluminium (AAA)
4 Emirates Engineering Services &
1400
Factories (EESF)
5 1500 Gulf Spring Contacting (GSC)
6 1600 Al Ahli General Transport (AGT)
8Special Organization Considerations

 None Identified

Forms

 Maintenance Order form

Reports

The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.

# Report Name Transaction Code


1 Order List IW39
2 Notification list IW28

Conversions

 None Identified

Functional Gaps / Enhancements / Approaches to Functional Deficit

 None identified

Workflows
 None identified

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6.4 AAHG_PM_004 – Refurbishment Process

As-Is Process

 Currently there is no system for repair those repairable spare part, and then return that
spare part back to the equipment, or to warehouse.

Process Overview

This process will help maintenance supervisor to track those High value repairable spare parts
and track the cost of total process from order creation to returns the refurbished spares to
warehouse

To-Be process

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Process Steps:

Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

1 Creation of Re- M SAP Iw81 Maintenance This order will be used for
furbishment order Supervisor usually high value- defec-
tive repairable spares to
be refurbished
2 M SAP IW32 Maintenance
Release of the Orders needs to be re-
order Supervisor leased for execution

3 Material with- M SAP MIGO Stores In-


Store people issue the
drawal of Refur- charge material for refurbishment
bishment
4 Time confirma- M SAP Iw41/iw Maintenance Actual duration and mate-
tion of the Refur- 42/iw48 Supervisor rial consumed for the re-
bishment furbishment of the order
5 Goods receipt of M SAP IW8W Stores In-
Refurbished material will
the refurbished charge hand over to store
material
6 M SAP MMBE Stores In- Refurbished material
Check material charge quantity will be updated in
stock the respective category
of the material
7 Display of the M SAP MM03 Stores In- Valuation details will be
material charge updated as per the mate-
rial
8 Run settlement M SAP KO88/K Finance Settlement is done by fi-
cycle O8G nance people
9 Business comple- M SAP IW32/C Finance Close the order to indicate
tion of Order O99 business completion is
done for the order.

Business Situation

Before creating the refurbishment order the same will be treated as material with valuation
details and updated in the stock.

If it is internal process after refurbishment stock with details will be updated in the refurbish-
ment valuation category

If it is external process PR will be created for material. It will be sent to outside for repair. Af-
ter refurbishment material sent back to warehouse and updated valuation category details of
stock.

Scope

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# Company Code Company Name


1 1100 Al Ahli Plastics Industries (API)
2 Emirates General Contracting
1200
(EGC)
3 1300 Al Ahli Aluminium (AAA)
4 Emirates Engineering Services &
1400
Factories (EESF)
5 1500 Gulf Spring Contacting (GSC)
6 1600 Al Ahli General Transport (AGT)
8Special Organization Considerations

 None Identified

Forms

 None Identified

Reports

The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.

# Report Name Transaction Code


1 Order list IW38
2

Conversions

 None Identified

Functional Gaps / Enhancements / Approaches to Functional Deficit

 None identified

Workflows
 None identified

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6.5 AAHG_PM_005 – Preventive Maintenance Process

As-Is Process


Currently there is no system for preventive maintenance process for doing the mainte-
nance activities as per manuals/user recommendations.
Process Overview
When we purchase new equipment or for existing equipment’s this process will help to track
the maintenance due activities as per the manuals / user recommendations.

Based on historical quality data and technical experience, are going to change the plan Fre-
quency accordingly. Decision will be taken by maintenance HOD.

To-Be process

Preventive Maintenance

ST AN D AR D D EC ISION
SAP
Event

Start End
PR OC ESS PR OC ESS
ST AR T EN D
M AN U AL M AN U AL
IN PU T OPER AT ION

System creates a
System

Preventive
Notification – PM type
Manager

Release the
maintenance
order

Identify
Create PM03
Schedule of List all PM - technician
Is Maintenance type Component Stock System creates
Preventive Preventive Y Y Y for
Order required.? Maintenance required.? available reservation no
Maintenance Plan Notifications type preventive
Order
maintenance
Maintenance Supervisor

N N

Confirmation of External System creates


Update technical N
Order if service Y Purchase
findings
necessary required.? requisition

Close PM03
Preventive Close PM
Maintenance Notification
Order

N
Technician

Execute
Work

Goods
Purchase
MM

Receipt / Goods Issue


Order
Service process
process
Receipt

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Process Steps:

Step Process Step M/O SAP/ T-code Role Remarks


# Description Man-
ual

1 Create Mainte- M SAP IP11 Maintenance Create maintenance strat-


nance strategy Planner egy ( i.e. weekly, fort-
nightly, monthly quarter-
ly, half yearly yearly
2 M SAP IA05/IA Maintenance Create a Task list(i.e.
01/IA11 Supervisor general task list or specific
Create task list to Equipment or Function-
al location ) as per re-
quirement
3 M SAP IA05/IA Maintenance As per requirement re-
Assign Strategy
01/IA11 Supervisor spective strategy needs to
to task list
be added to task list
4 M SAP Ip41/ip Maintenance Create the maintenance
Creation of 42 Supervisor plan as per the require-
maintenance plan ment and assign task list
and maintenance strategy
5 M SAP IP10/IP Maintenance As per the plan orders will
Schedule of 30 Supervisor be triggered after schedul-
maintenance plan ing of the plan

6 Release and exe- M SAP IW32 Maintenance


Maintenance work will be
cution of the or- Supervisor carried out here
ders
7 Time confirma- M sap IW41/I Maintenance Time related information
tion of the orders W42/IW Supervisor will be entered for the re-
48 spective orders i.e. actual
time taken to complete
the order
8 Run settlement M SAP KO88/K Finance Settlement is done by fi-
cycle O8G nance people
9 Business comple- M SAP IW32/C Finance Close the order to indicate
tion of Order O99 business completion is
done for the order.

Business Situation
The Engineering maintenance Engineer will prepare the frequency & preventive maintenance
plan for the technical object which required for maintenance.

Based on preventive maintenance schedule maintenance HOD will prepare the maintenance
schedule plan for one month for better monitoring.

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Schedule chart is prepared and distributed to Foreman/Supervisor, Production head and Engi-
neering head.

As per the recommended schedule plan, machine checklist will be issued to the foreman for
executing all the activities based on the check list.

All the information will be updated in the Maintenance orders of technical objects.

Scope

# Company Code Company Name


1 1100 Al Ahli Plastics Industries (API)
2 Emirates General Contracting
1200
(EGC)
3 1300 Al Ahli Aluminium (AAA)
4 Emirates Engineering Services &
1400
Factories (EESF)
5 1500 Gulf Spring Contacting (GSC)
6 1600 Al Ahli General Transport (AGT)
8Special Organization Considerations

 None Identified

Forms

 None Identified

Reports

The following table lists the most frequently used standard reports that help to obtain addi-
tional information on this business process.

# Report Name Transaction Code


1 Preventive Maintenance schedule IP19 / IP24

Conversions

# Requirement Description
3 AAHG-PM-CON-003 Task List
4 AAHG-PM-CON-004 Preventive Maintenance Plan

Functional Gaps / Enhancements / Approaches to Functional Deficit

 None identified

Document Name & Version : Document1


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SAP Business Blueprint
Plant Maintenance

Workflows
 None identified

Document Name & Version : Document1


Page Number : Page 46 of 50
SAP Business Blueprint
Plant Maintenance

7 Solution Design
The purpose of this section is to describe configuration required in Materials Management in
SAP.

7.1 Organization Structure

7.1.1.1 Maintenance planning Plant


Planning plant Name1 Name2
1000 Al Ahli Holding Group (AAHG)
1100 Al Ahli Plastics Industries (API)
Emirates General Contracting
1200
(EGC)
1300 Al Ahli Aluminium (AAA)
Emirates Engineering Services
1400
& Factories (EESF)
1500 Gulf Spring Contacting (GSC)
Al Ahli General Transport
1600
(AGT)
1700 Comicave Studios - Singapore
Comicave Toys & Games Trad-
1800
ing –Dubai
Al Ahli Publishing and Distribu-
1900
tion (APD)
2000 Little Manila
2100 Dubai Outlet Mall (DOM)
2200 Gold’s Gym International (GGI)
2300 Rethink Leisure Entertainment
2400 Universal Events

7.1.1.2 Assign Maintenance Planning Plant to Maintenance plant


Plant Name1 PIPI Name1
Al Ahli Holding Group Al Ahli Holding Group
1000 1000
(AAHG) (AAHG)
Al Ahli Plastics Indus- Al Ahli Plastics Indus-
1100 1100
tries (API) tries (API)
Emirates General Emirates General
1200 1200
Contracting (EGC) Contracting (EGC)
Al Ahli Aluminium Al Ahli Aluminium
1300 1300
(AAA) (AAA)
Emirates Engineering Emirates Engineering
1400 Services & Factories 1400 Services & Factories
(EESF) (EESF)
Gulf Spring Contact- Gulf Spring Contact-
1500 1500
ing (GSC) ing (GSC)
Al Ahli General Al Ahli General
1600 1600
Transport (AGT) Transport (AGT)
Comicave Studios - Comicave Studios -
1700 1700
Singapore Singapore

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SAP Business Blueprint
Plant Maintenance

Comicave Toys & Comicave Toys &


1800 Games Trading – 1800 Games Trading –
Dubai Dubai
Al Ahli Publishing and Al Ahli Publishing and
1900 1900
Distribution (APD) Distribution (APD)
2000 Little Manila 2000 Little Manila
Dubai Outlet Mall Dubai Outlet Mall
2100 2100
(DOM) (DOM)

7.1.1.3 Define Planner Groups

PIPI PG Name Telephone


1000 100 Maintenance Planner
1100 100 Maintenance Planner
1200 100 Maintenance Planner
1300 100 Maintenance Planner
1400 100 Maintenance Planner
1500 100 Maintenance Planner
1600 100 Maintenance Planner
1700 100 Maintenance Planner
1800 100 Maintenance Planner
1900 100 Maintenance Planner
2000 100 Maintenance Planner
2100 100 Maintenance Planner

7.1.1.4 Define Notification Types

Notification Notification category Notification Number


Type origin range
M1 PM Notification Maintenance
Request
M2 PM Notification Malfunction
Report
M3 PM Notification Activity Report

7.1.1.5 Configure Order Types

Order Cate- Order Type Settlement Number


gory profile range
30 PM01(Corrective Mainte-
nance order)
30 PM02(- Breakdown Order)

30 PM03(Preventive Mainte-
nance order)
30 PM04(Refurbishment Order)
30 PM05(Calibration Order)

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Plant Maintenance

7.1.1.6 Define Maintenance Activity Types

MAT MAT Description


MAL Malfunction
BDN Breakdown
CMA Condition monitoring
activities
OVH Overhauling
INS Inspection
MRQ Maintenance request
ECV Energy conservation
EEE Equipment effective-
ness
PCR process change
SFT Safety improvement
ROT Routine servicing

8 Gaps
 None Identified

9 Enhancements

 None Identified

10 Annexure -1 : Layouts

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Plant Maintenance

 None Identified

11 Annexure -3 : Custom Reports

None Identified

End of the Document

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