SAP PM
Avnikant Singh
Introduction
• My name is Avnikant Singh and currently working with MNC
• Has total 12 + years of experience of SAP in consulting
experience in SAP EAM,PM modules within different domains
like utilities, chemical, manufacturing, Oil and Gas etc.
• Worked in multiple roles within my career with different
global clients in US ,EU.
• Worked on multiple SAP implementation , upgrade ,roll
out ,support , go-live Projects with different companies like
TCS,PWC,BM and other product-based companies.
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What we will learn
SAP Overview
Plant maintenance in R/3 system
Plant maintenance an overview
Organization structure
Master data in SAP PM
Maintenance process
T-codes , tables and configuration
S/4 HANA and ECC difference 3
AGENDA
What is ERP
Various ERP Products in Market
Introduction to SAP
SAP R/3 Application and S4/HANA
Technical and Functional Modules
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WHY ERP
• Manage business functions within a centralized and
integrated system
• Information shared within different department of orgz
• Overall control of organization
• Better reporting system
• Best utilization of resources i.e.-Man Material and machine
• Depart: purchasing ,FI, Planning, Engineering, PROD,
Quality ,HR, Warehouse, Sales, Customer service ,Projects
Various ERP Products in Market
SAP, Oracle, Microsoft, Infor
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With SAP S/4HANA, SAP delivers a new product, which is completely based on the
in memory platform SAP HANA. SAP S/4HANA is not an upgrade of the existing
Business Suite
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Highlights for SAP S/4HANA
• Successively renewed coding of all SAP
applications based on SAP HANA
• Radically simplified data model (redundant tables
and indices removed)
• SAP Fiori as new User Experience
• Substantially reduced data footprint
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Deployment Options
On-premise --In this common model, the customer
acquires a license and installs the software in their
own data center.
Cloud --In this model, the customer rents the
software for a certain period of time. SAP deploys
the software in the SAP-owned data centre.
Hybrid-- In this model, required applications are
operated partially by the customer and partially by
SAP in the cloud. Both parts can be linked and
integrated with each other.
Mobile --In this model, mobile devices access on-
premise, or cloud applications.
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SAP EAM and PM
SAP EAM is a packaged solution for asset operators
supporting the entire life cycle of assets .
SAP EAM uses the available functionality of the mySAP
business suit. SAP PM is a major part of it.
This helps the companies to maximize their potential,
save time and money. The process also optimizes
business risks and reduce risks.
The SAP PM (Plant Maintenance) module is a subset of
SAP EAM (Enterprise Asset Management).
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Methodology
The SAP S/4 HANA implementation Activate methodology
consist of a six-phase project lifecycle. The six phases
are:
•Discover – Define goals based on where your company
is within its SAP journey. This phase involves technical
research, which is conducted by your SAP SuccessFactors
consulting partner.
•Prepare – Set up a project plan, which will draw upon
details from the Discover phase, including your migration
strategy and IT management
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approach.
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•Explore – Refine business requirements, confirm
businesses processes, review details and prepare for
implementation and system conversion.
•Realise – Development environment build and test
the configuration and migration process while
finalising end-user training materials and
documentation,
•Deploy – Setup the production system and IT
infrastructure, migrate organization data and
complete all end-user training.
•Run – Make adjustments to system settings,
configure new tools, and take other steps to fine-tune
the software now that it’s deployed.
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SAP PM overview
SAP Plant Maintenance (SAP PM) application component provides an organization with a
tool for all maintenance activities to be performed. All the activities that are performed
under maintenance are interconnected and hence this module is closely integrated with
other modules - Production Planning, Material Management, and Sales and Distribution.
Using SAP PM, you can perform automatic repairs and facilitate maintenance requests in
an organization. It allows you to record problems in SAP system, plan labor and material
activities, and to record and settle the cost.
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SAP PM Structure
SAP Plant Maintenance (SAP PM) is a software product that manages all maintenance activities in an organization.
Client
Company Code
Plant
Maintenance plant Planning plant
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Sequence for Defining the Organizational
Levels
After an in-depth analysis, the organizational
units relevant for Plant Maintenance are
defined in the system.
Maintenance plants (which, usually, already
exist as logistical plants) and maintenance
planning plants (planning plants for short) are
defined in the company structure.
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Structured Organizational Levels
Client :The Client is the highest-level element
of all the organizational units. It corresponds to
a corporate group with several subsidiaries.
Within a client, the system always accesses the
same database.
Controlling Area :From the Controlling
perspective, one or several company codes are
assigned to a Controlling Area to have a
common Controlling/Management Accounting
over several subsidiaries.
Company Codes :The subsidiaries, with their
own financial statements and balance sheets,
are defined as Company Codes. Plant The Plant
at which the operational systems of a company
are installed is called the maintenance plant.
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Planning Plant
Planning Plant: If maintenance work is planned at this plant,
the maintenance plant is also the maintenance planning
plant. Locations subdivide a maintenance plant according to
location-based criteria, such as site, buildings, and
coordinates. A maintenance plant can also be subdivided into
plant sections based on responsibility for production. The
person responsible for the plant section is the contact person
who coordinates production and maintenance (the plant
engineer). A Maintenance Planning Plant (Planning Plant for
short) is the organizational unit in which maintenance
requirements are planned. These requirements can either
come from your own plant or from another maintenance plant
assigned to this maintenance planning plant. The planners
within a maintenance planning plant are defined by
maintenance planner groups.
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Plant-specific planning: (1:1 mapping)decentralized- A
Maintenance plant is also known as a Maintenance planning
plant. In most organizational structures, maintenance
measures are planned in the same plant where the
maintenance requirement occurs. The maintenance orders are
executed by workshops from the same plant, and the spare
parts are stored in the same plant (for example, plant 1000).
Cross-plant planning: (1:n mapping) centralized-
Multiple maintenance plants are assigned to a planning plant.
For example, in a plant (for example, plant 1200) needs for
maintenance because a technical system there requires
maintenance (maintenance plant). All further functions
(maintenance planning, order execution, and spare parts
storage) are however, the responsibility of another plant.
Other options are also possible. The planning of a plant's
maintenance measures (for example, plant 1300) and the
spare parts procurement take place in another plant (plant
1000). However, the tasks are performed by workshops that
are available locally.
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PM DATA
Master data : Data that remains unchanged over a period. It
contains information that is always needed in the same way.
Work center, FLOC , EQUIP, class, task list , MPLAN, catalog,
BOM, measuring point ,Permits ,warranties, Maintenance
Strategy
Transactional Data :Data relating to the day-to-day
transactions.
Order , Notification , measuring Document.
Configurational Data: Data which is configured based on
business requirement
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PM Master data
Master data Where used
Equipment, functional locations, work centres, materials,
Classes/characteristics task lists, etc.
Master Warranties Equipment
Permits Equipment, functional locations, orders
Work centres Equipment, functional locations, orders, notifications
Equipment, functional locations, orders, notifications,
Materials BOMs
Functional locations Orders, notifications, Task Lists, BOMs, maintenance items
Equipment (serial numbers) Orders, notifications, Task Lists, BOMs, maintenance items
Measurement points Equipment, functional locations
PRTs (equipment, material, etc.)
BOMs Equipment, functional locations
Task Lists Equipment, functional locations, orders
Maintenance items/plans
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Consulting Tips on Master data
During design phase we must remember following
points:
Dependency of master data on each other must be explained to client.
• Bill of material cannot be created without material master.
• Measuring points and counter has dependency on equipment, functional
location and characteristics.
• Serial number has dependency on material master and equipment.
• Equipment and functional location has dependency on Main work center
Always explain the difference between equipment and functional location to
business.
Clarify the importance of number range of equipment (external and internal).
Material master needs coordination with MM and FICO modules. Target to finish
it at early stage.
Maintenance plan category can control triggering of maintenance call
object(order/notif). This must be explained and finalized in design phase.
Master inspection characteristics are assigned to task list operations and used in
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Work center
• A work center is an organizational unit where work
can be carried out.
It can be -A machine, A group of machines ,A person ,
A group of people
• Work center data forms the basis for cost ,
capacity.
• It specifies which machine or person should be
used for operation
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Work center overview
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Work center configuration
Work center
• category --0005
• field selection
• screen sequence
• default work center
The transaction codes for working with work centers are:
Create work center: IR01
Edit work center: IR02
Display work center: IR03
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Work center Data
Basic data contains general data such as the work center category, description, and
usage.
We can link a work center to the following objects:
• Cost center
• Qualifications
• Positions
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• People PRESENTATION TITLE 24
Work Center
Main work center is the work center for which
maintenance department is responsible or where
maintenance operations are performed whereas
work center in location tab is production work center/
resource.
Integration :PM----PP
In Maintenance header the work center which is
displayed is copied from the equipment or the functional
location on which the Maintenance order is been
generated it is the Main work center for maintenance
tasks which is in the organization tab of functional
location or Equipment.
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Cost center Technical obj and Work
center
Technical Object Cost Center:
Technical Object cost center are referred as cost receivers and Work Order Cost will be
settled to this cost center.
Work Center Cost Center:
Work Center Cost Centers are used to calculate the cost of the work done (Labor
Work). This is the responsible cost center for the work order. This also requires
assignment of cost center in the work center and maintaining the Activity Pricing.
Settlement receiver is picked from Equipment Cost
Center.
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Also, We can see both the cost centers in the work
order
• Equipment Cost Center in Location Tab under
Account Assignment
• Work Center Cost Center in Additional tab.
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Maint. activity type and Activity type
PM Activity types (IW32 header tab) are used mainly for
reporting purposes. Cost reports are classified and can be
reported based on PM Activity types.
These Activity types are configured and assigned to Order
types for default settings. Activities are divided into repairs,
shutdowns, regular activities, inspections and so on.
Activity types (Work center) are created through [Link]: KL01
and these activity types are assigned in the work center. Activity types are
assigned to the cost center in [Link]: KP26 where the cost for labor / hour
is defined. The cost center is assigned to the work center.
When the work order operations are scheduled the activity type defaults
from the work center for cost calculations on the labor costs.
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Activity Price (KP26):
Activity price is maintained in combination with Cost
Center and Activity type.
The cost of the labor utilized in the work order is
calculated based on the Cost Center assigned to the
work center.
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Functional location
overview
The business object functional location is an
organizational unit within Logistics, that structures the
maintenance objects of a company according to
functional, process-related or spatial criteria. A
functional location represents the place at which a
maintenance task is to be performed.
A functional location represents system area at which
an object can be installed. Objects that can be installed
at functional locations are called pieces of equipment
in the SAP System.
We can structure functional locations according to the
following criteria: Functional
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Criteria, Process-related
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criteria, Spatial Criteria.
You can structure functional locations according to the following
criteria: Functional Criteria, Process-related criteria, Spatial Criteria.
spatial criteria :(for example, building 1 and building 2),
technical criteria: (for example, press, press frame, and press
hydraulics),
functional :- that is, process-oriented - criteria (for example,
polymerization and condensation).
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FLOC configuration settings
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Structure Indicator
The structure of a functional location is based on the
structure indicator.
The structure indicator consists of the following input
fields:
Edit mask --used to control which characters can be used
for identification (letters, numbers, special characters or
all three)
Hierarchy Levels--used to define which level ends at
which character and how many hierarchy levels the
structure can contain.
A functional location can
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Functional location represents the place at which maint. Task
is to be performed.
Functional location is physical location in the plant which is
immovable entity and is well defined in terms of plan of the
facility.
For example :-a polymer plant
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XXXX XXN XXXXX XXXXXN
1 2 3 4
Level 1 plant
level 2 unit
level 3 department
level 4 Machine
Equipment installation :
The fields here are optional. If equipment needs to be installed on this functional
location, then the checkbox Equi-installation allwd should be marked.
Single installation :indicator shows whether only a single piece of equipment or several
pieces of equipment can be installed at this functional location at the same time.
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In FLOC we have multiple scenarios:
Reference Functional Locations:
You can use a reference functional location to help create and manage several similar
functional locations in the system. Define and manage reference functional locations in
individual master records. Reference functional locations do not represent actual locations;
they are assigned to real functional locations as reference locations.
The system manages the master records for reference functional locations at the client
[Link] means that their labels are unique for an entire corporate group.
Copying a Complete Functional Location Structure
To represent a location structure that already exists in a similar form in the system, use this
structure as a template for the new structure. You can use this function if the data of the
similar structure has already been saved, and you can use this function to access the
database and select the objects to be copied.
Data Origin
There are some fields which are having inheritance option from Superior Functional Location.
While creating the new FL, once you enter the Maintenance Plant, you can have the option to
derive the details (Cost centers, work center, planner group, etc.,) from superior FL.
These fields can be maintained either manually or derived from superior FL.
In the Data origin list, you can see the fields list which are having this functionality. Based on
the field data, check mark would be ticked against either Maintained manually or
Superior FL.
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Alternative Labeling
In alternative labeling of functional locations, you can
change labels for functional locations.
SAP alternative labeling of functional locations:
• used when a client wants to use a legacy naming convention along with
a new SAP naming convention. That means you can assign multiple
labels to the same Functional location. The most used label is defined
as primary label and all other as secondary labels.
• use SAP alternative labeling of functional locations also when accidently
you entered an incorrect label of a functional location and want to
correct it without making a new entry.
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Plant Maintenance and customer service > Master
Data in Plant Maintenance and Customer Service >
Technical Objects > Functional Locations >
Alternative Labeling of Functional Locations >
Activate Alternative Labeling
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Key Note:
When Alternative Labeling is
activated a new table IFLOS is
created in addition to the
existing table ILFOT.
The new table IFLOS contains
the alternative labels, the old
table IFLOT contains the
standard fields. Both tables are
linked via the primary key of
the functional location.
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Equipment
SAP equipment represents a physical object which can be independently maintained
in the industry. A piece of equipment can be installed at functional locations
Equipment is an asset that can be moved from one place to another. Examples of
equipment can be transportation utilities, measurement devices, PC systems,
machine spare parts, etc.
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Equipment Category
To structure equipment categories , we can use the object type (also for
functional locations). For example, if the equipment type is fleet object,
then the object types can include car, truck, and motorbike.
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Thank you
Avnikant Singh