SAP PM MODULE

BUSINESS
PROCESS
The need for Information

Vision
An Integrated, Flexible and Standardised Information
Systems architecture to position towards
fundamental competitive advantage

SAP
for Enterprise-wide
Transformation.

Current Reality
Function based Organisation, Multiple stand alone packages,
Time lag between market realities and decision making
SAP R/3 – The Integrated Enterprise

SD FI
Sales & Financial
Distribution Accounting
MM CO
Materials
Mgmt. Controlling
PP AM
Production

SAP
Fixed Assets
Planning Mgmt.
QM EC
Quality Enterprise
Manage- Controlling
ment PM
Plant Main-
tenance
R/3 IM
Investment Mgmt

LDM
Lifecycle
Client / Server PS
Project
Data Mgmt ABAP/4 System

IS-Oil CIN
Navigating SAP R/3
Navigation Topics

 Logging On
 SAP Window components
 Using the Navigation Area
 Transaction Codes
 Role Based Menu
 Standard Tool Bar
 SAP Easy Access
 User Settings
 Messages
 Online Help use
Logging on

Required Fields
Client

User

Password

Language
 The SAP Window
Menu Bar

Screen Banner Standard Tool Bar

Screen Header
Title Bar
Application Tool Bar

Screen Body

Insert/Overtype Indicator

Server

SAP System ID
Status Bar
Using the Navigation Area

 You can expand and

collapse menus in the
navigation area by
choosing the dropdown
arrows to the left of the
menu items, as in the
example below

 To open an application in
the navigation area
Double-click its node
Transaction Codes

 A transaction code can be entered in the Command field.

 If you precede the transaction code
with /n then the transaction is the
next screen opened in the current session.
 If you precede the transaction code
with /o then a new session is opened
for the transaction. This means you then have multiple sessions.

 To start a transaction in SAP 4.6, there are 4 options:

 Position the cursor on the required transaction in the tree structure and press
enter
 Double-click on the required transaction in the tree structure
 Position the cursor on the required transaction in the tree structure and select
Edit  Execute (or press F2)
 Expand the command field and enter the transaction code
 Standard Toolbar

 The Standard Toolbar contains the Command field and the

standard SAP Toolbar buttons.

 Command Field: The Command field is used to enter transaction

codes that take you directly to a system task without using
menus.

Button Keyboard Shortcut Description Button Keyboard Shortcut Description

Enter Key Enter/Continue Ctrl + Page Up First page

Ctrl + S Save to database Page Up Previous page

F3 Back Page Down Next page

Shift + F3 Exit System Task Ctrl + Page Down Last page

F12 Cancel None Create New session

Ctrl + P Print None Create shortcut on Desktop

Ctrl + F Find F1 F1 Help

Ctrl + G Find next Alt + F12 Customize Local Layout

SAP Easy Access Settings

 Users can set how SAP displays the Menu by choosing Extras  Settings. Here,
you can specify whether:

 Your favorites should appear before or after the menu

 Only your favorites, and not the menu, should appear

 The SAP Easy Access graphic should appear on the right-hand side of the
screen.

 Technical names of menu options should appear in the navigation area

User Settings

 Users can maintain their own settings by choosing System  User Profile  Own
Data

 Defaults

 Change default printer, language, and date and decimal display formats.

 Parameters

 Allow user to create default information for frequently used fields.

Messages

 Messages appear either in the status bar or in a pop-up window, depending on

user settings
 Messages starting with:
 “E” indicate an Error message
 “W” indicate a Warning message
 Messages not beginning with an “E” or a “W„‟ are simply Information
messages
 Required fields are denoted by a check mark
Using Online Help

 Field Level Help

 Used to describe what a
currently selected field is
designed to do.
 Click on the Help icon or „F1‟.

 Example:
 Find definition of Material number
 Click Material field
 Click Help button or press F1
key
 Click Cancel button to return
to the screen
SAP Mail

• SAP Mail system is used to send a mail to other users of SAP in.
• The recipient is identified by User ID of SAP e.g., STR_PM3, STR-PM1,.,
• SAP Mail can be used for sending information regarding a Notification,
order, equipment etc., through SAP screen or
• through the SAP menu by tcode SBWP (Sap Business work place) for a
normal message.

Procedure :
• In a SAP screen Go to
“services for object” .
• In the following screen click on
„Send‟ icon.
SAP Mail

• or use tcode „sbwp‟ and

follow as detailed below

• Enter message

• Enter recepient
• If the mail is required to
be attended immediately
check „Express mail‟

• Click „Send‟
Plant Maintenance
Overview
 Section

PM-01 Organization Structure

PM-01-01 – Organization Structure
 Organization Structure

Maintenance Planning Plant

Maintenance Plant

Functional
Locations Aeration Air Comp H2SO4 Boiler
BioSludge System Transfer Blowers
Organization Structuring – 1/5

Client

Company Code (s)

A grouping of legal,
organizational, business
and/or administrative
Plant (s) units with a common
purpose. Single database
Maintenance Plant

Maintenance Planning
Plant
Organisation Structuring – 2/5

Client

Company Code (s) Represents an independent

accounting unit within a
client. Each company code
Plant (s) has its own balance sheet
and its own profit and loss
Maintenance Plant
statement.

Maintenance Planning
Plant
Organisation Structuring – 3/5

Client

Operational unit within

Company Code (s) a company code.
•Material Valuation
•Inventory Management
Plant (s) •Material Master

Maintenance Plant

Maintenance Planning
Plant
Organisation Structuring – 4/5

Client

• Maintenance Objects
Company Code (s) • Work Centres
• Same as Plant

Plant (s)

Maintenance Plant

Maintenance Planning
Plant
Organisation Structuring – 5/5

Client

Company Code (s) Planner Groups

• Task lists
Plant (s) • Maintenance Plans
• Order Creation
Maintenance Plant • Resource Planning
• Work Scheduling
Maintenance Planning
Plant
 Definition of the Organization Elements

 Company Code: The smallest organizational unit for which a complete

self-contained set of accounts can be drawn up for purposes of external
reporting.

 Maintenance Plant: Plant, in which the technical objects of a company

are installed.

 The planning responsibility for a maintenance plant is defined by using

a planning plant. Maintenance plants are assigned to maintenance
planning plants.

 Maintenance Planning Plant: Plant in which maintenance tasks are

planned and prepared.These tasks can relate to technical objects in
your own plant or in other plants.Maintenance planning plants are
normal plants that are indicated as maintenance planning plants in
Customizing. Maintenance plants, which do not plan their own
maintenance tasks, are assigned to the planning plants. Planning is
performed for the maintenance plants in the planning plants entered.
Section

PM-02 Master Data

PM-02-01 – Functional Location
PM Functional Location

A functional location is an element in a technical structure, representing an

area/spatial/functional of a Plant at which
Equipment/s can be installed.
Structure Indicator

Edit Mask – xxx-xxx-xxx-xxxx-xxx-xxxxx

Hierarchy levels 1 2 3 4 5 6

LEVEL 1

LEVEL 2

LEVEL 3

LEVEL 4

LEVEL5

LEVEL6

LEVEL 7
Functional Locations-Criteria

Criteria for Functional Location :

 Execution of Maintenance Tasks
 Recording of Maintenance Task
 Data Collection over long periods of time
 Cost Monitoring by Area
 What affect do the Usage Condition have on the
likelihood of Damage to the installed aggregates.
 Used normally for the object which are not movable.
Understanding the Transaction

PM-03-02-01 Master Data – Functional Location

 Functional Location Structure using Tcode IH01
 List Display of Functional location using Tcode IH06
Section

PM-02 Master Data

 PM-02-02 – Equipment
Equipment-Criteria

Criteria of Equipments :

 Management of Individual Data

 Recording of Maintenance tasks
 Object based recording of costs
 Evaluation of technical data
 Recording of Usage Times
Equipment Usage List
 Understanding the Transaction

PM-03-02-02 Master Data – Equipments

 Equipment Structure using Tcode IH03
Section

PM-02 Master Data

 PM-02-03 – Measuring Points
Measuring Points

 Measuring points in the R/3 System describe the physical and/or logical
locations at which a condition is described, (for example, the compressor
discharge pressure).

 Measuring points are located on technical objects ie. on pieces of

equipment or functional locations.

 Measuring Point can be either a parameter value or a counter.

 Measurement Readings are entered for the measurement point with

reference to a specific time.

 Notifications can be generated automatically if the value of the measuring

reading exceeds the range specified in measuring point.

 Measurement and counter readings are stored in the system in the form
of measurement documents. These documents are the basis for
performance-based maintenance planning
 Understanding the Transaction

PM-03-02-03 Measuring Points

 Display Measuring Point using Tcode IK03
 Create Measurement Document using Tcode IK11
Section

PM-02 Master Data

 PM2-02-04 – Bill of Material(BOM)
Bill of material

Bill of Materials (BOMs)

–A complete, formally structured list of the components making up a technical object

–The list contains the individual components together with their quantity and unit of measure

–The components can be stock or non-stock spares or assemblies

Purpose
–Material/spare parts planning

•to assign materials/spare parts to a maintenance order.

–Locating malfunctions

•to locate the malfunction in the piece of equipment or in its bill of material for a
maintenance notification.

–Material assignment

•to assign material to the individual operations of a task list.

Bill of material – for equipment

Equipment - 10006767
Centrifugal Pump”

Equipment BOM

10 Casing type A 100-100 1 PC

20 Impeller 100-200 1 PC
30 Seal 100-300 4 PC
40 Shaft 100-400 1 PC
50 Sleeve 100-500 2 PC
60 Bearing - A 100-600 1 PC
70 Bearing - B 100-700 1 PC
80 Wear Ring A 100-800 2 PC
90 Wear Ring B 100-900 1 PC
 Understanding the Transaction

PM-03-02-04 BOM
 Display Equipment BOM using Tcode IB03
 Display Functional Location BOM using Tcode IB13
Section

PM-02 Master Data

 PM-02-05 – General task List
Plant Maintenance task list – Check list

SEQUENCE OF INDIVIDUAL MAINTENANCE TASKS

WHICH REPEATEDLY HAVE TO BE PERFORMED ON A
MACHINE OR AT A SPECIFIC AREA.

THESE TASKS ARE , FOR EXAMPLE :-

• INSPECTIONS - Determining the actual condition.
• MAINTENANCE - Maintaining the ideal condition.
• REPAIRS - Restoring the ideal condition.
 Task List

Maintenance task lists describe a sequence of individual maintenance activities

which must be performed repeatedly within a company. The functions for
creating data in equipment task lists, functional location task lists and general
maintenance task lists are very similar and will therefore be dealt with jointly in
this section.

1. You create operations and, where necessary, sub-operations and enter detail
data for internal or external processing.

2. You can include user data in the operations or sub-operations, as required.

3. You can assign the following objects to the operations:

 Material components
 Production resources/tools
 Maintenance packages
 Inspection characteristics
 You can arrange the operations according to time by
defining relationships.
 You can perform a cost analysis.
 Task list categories

Functional location
FL1 FL2

TL TL
Op. 1 Op. 1
Op. 2 Op. 2
Op. 3 Op. 3 Task
list
categories
Equipment General task lists

Equipment 1 Equipment 2 Pumps Cleaning

TL
TL
Op. 1 Op. 1 Op. 1 Op. 1 Op. 1 Op. 1
Op. 2 Op. 2 Op. 2 Op. 2 Op. 2 Op. 2
Op. 3 Op. 3 Op. 3 Op. 3 Op. 3 Op. 3
Task List Group Counter
 Understanding the Transaction

PM-03-02-05 Task List

 Display Equipment Task List using Tcode IA03
 Cost Maintenance Task Lists using Tcode IA16
 Material Where used list: Task List using Tcode IP62
Section

PM-02 Master Data

 PM-02-06 – Maintenance Plan
Types of Preventive Maintenance

Preventive
Maintenance

Time-based Performance-based

2001
Maintenance Plans

Maintenance plan

Single cycle plan Strategy plan Multiple counter plan

Time-based Performance-based
Maintenance Plans
Maintenance Plan Functions
Scheduling Period

Schedule in future Order 901760

Maintenance plan displayed for the
specified scheduling
period

Scheduling data

Planned dates
Scheduling period
1 year
Maintenance item Orders

Cycle start Scheduling period

Call Horizon

Order 901760

Maintenance plan Scheduling data

Maintenance item Call date derived from

the call horizon
Planned date

Cycle
start
Cycle 3 months = 90 days
Call horizon at 90% = 81 days
Shift Factor

Maintenance plan Technical completion New planned date

30/07/2003 30/07/2003(shifted by
100%)
Scheduling data

Maintenance item

Planned date Planned date

Cycle 1 month
Shift factor 100%

Cycle start

Tolerances can be used in combination with Shift factors to control the

shifting of future planned dates
Cycle Modification Factor

Maintenance plan

Cycle modification
Factor
Scheduling data

1.5

Maintenance item

Planned date New planned date

Cycle
4.5 months
Cycle start 3 months
Scheduling Indicator

Scheduling Indicator

Time
“Time”
Cycle start 1 month = 30 days
Maintenance plan

Scheduling
indicator
Time-
key date
Scheduling data “Time key date”
Cycle start Falls due on exactly the
same date as per the cycle

Maintenance item

Time-
Factory cal.
“Time Factory calendar”
Cycle start Falls due as per the cycle with
factory calendar as the
reference for calculating time
Deadline Monitoring

Order 901760

Order

Orders for the

next 90 days

Deadline monitoring

Cycle 1 month

Date of deadline = Planned dates

monitoring run
Maintenance Packages Hierarchy

Same hierarchy levels

Strategy

H1

H1 All the packages are executed which fall due on the same date

Different hierarchy levels

Strategy

H1

The maintenance package with the higher hierarchy suppresses

H the lower one when both packages fall due on the same date
2
Maintenance Strategy

Scheduling indicator Strategy unit Package definition

Time Shift factors 3 months
Time – using key date Tolerances 6 months
Time using Fact. calendar Factory calendar

Maintenance Strategy
Scheduling Parameters
 Understanding the Transaction

PM-03-02-06 Maintenance Plan

 Display Maintenance Plan using Tcode IP03
 Schedule Maintenance Plan using Tcode IP10
 Scheduling of Maintenance Plan using Tcode ZPMIP30
 Maintenance Plan Cost Display using Tcode IP31
 Maintenance Cycle Set using Tcode IP11Z
 Add Multiple Counter Plan using Tcode IP43
 Maintain Maintenance Strategies using Tcode IP11
 Add Strategy control Plan using Tcode IP42
Section

PM-02 Master Data

 PM-02-07 – Catalogs
CATALOGS

CATALOG PROFILES

CATALOG TYPES AND

CATALOG CODE GROUPS

CODES AND DESCRIPTIONS

In PM, only the catalogs type 2,5,A,B,C is used.

Catalogs
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -1/5

CATALOG TYPE-(B)
(OBJECT PARTS)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -2/5

CATALOG CODE (2)

(TASKS)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -3/5

CATALOG CODE (C )
(DAMAGES)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -4/5

CATALOG CODE (5)

(CAUSES)
CATALOG PROFILE(RECIPROCATING COMPRESSOR) -5/5

CATALOG CODE (A)

(ACTIVITIES)
 Understanding the Transaction

PM-03-02-07 Catalogs
 Maintain Catalog using Tcode QS41
Section

PM-02 Master Data

 PM-02-08 – Work Center
 Work Centers in PM

Work center : An Organizational unit.

 It defines where and by whom an operation is to be performed.

Work Center in PM Module will be :
 Group of Persons for eg. Multi Disciplinary team / Electrical /
Mechanical / Instrumentation Team.
 The work center is specified in master data of equipment or
functional location, maintenance item, task list header,
operations of task list, order header and order operations.
Work Center Contents
Work Center : Main Functions
 Understanding the Transaction

PM-03-02-08 Work Center

 Display Work Center using Tcode IR03
Section

PM-02 Master Data

 PM-02-09 – Warranties
 Warranties

 Warranties define the scope of the services that a Vendor

should provide for a technical object in the event of damage or
problems for the validity period.

 Warranties to pieces of equipment of functional locations.

Warranty in PM is :
 Vendor Warrantee (for example, manufacturer or vendor
warranty)
Structure of Warranty

Warranty type
Warranty Description
header Classification

Warranty Service activities

items inclusive/exclusive

Warranty
Counters , limits
counter
 Understanding the Transaction

PM-03-02-09 Warranties
 Display Master Warranty using Tcode BGM3
Section

PM-02 Master Data

 PM-02-10 – Classification and Permits
 Classification

 Classification system uses characteristics & values to describe all

types equipment, and to group similar equipment in classes.
 Classification helps in finding equipment more easily, using the
characteristics defined in them and values as search criteria.
 This also helps in finding equipment with similar or identical
characteristics.
Classification
Characteristics and Values

Type Centrifugal / Screw /Reciprocating

Capacity 50 m3/hr / 75 m3/hr / 100 m3/hr
RPM 975 / 1450 / 2900
Head 10 Mt / 20 Mts / 30 Mts
Stages 1/2/3
Fluid Oil / Water / Acids

Class
Maintenance Classification
Class PUMP Assignment of a pump to
class pump
–Type Assigned values
–Capacity Type - Centrifugal
Capacity - 75 m3
–RPM RPM - 1450
–Head Head - 10 mt
–Stages Stages - 1
–Fluid Fluid - Water

Locating a pump
Find a pump in Class PUMP with capacity = 75
m3
Permits (Technical Permits) / Process Permits
 Understanding the Transaction

PM-03-02-10 Classification and Permits

 Characteristics using Tcode CT04
 Classes using Tcode CL02
 Find objects in classes using Tcode CL30N
 Maintain Permit using Tcode IPMD
 Let us Get into Hands-
on right now

Now, let us start

understanding what we
discussed, better with
Hands-on Practice using
the Exercise Sheet PM-
02-10.
Section

PM-03 General
Maintenance Processing
PM-03-01 – Notification Processing
PM Notification Structure
Object Information

The Object Information contains

Structural Data, Classification
Data, Previous Damage, number
of days to solve the problem,
Previous notification
created/completed for the
technical object, maintenance
plans and documents for the
object.
Maintenance Processing

Maintenance Notifications for

 Reporting malfunctions, breakdowns

 Requesting for maintenance

 Documenting the activities performed

 Recording technical findings

 Technical history of an object gets updated upon
completion of notification.
Notification Types
Understanding the Transaction

PM-03-03-01 Notification Processing

 Create PM Notification using Tcode IW21
 Create PM Malfunction Report using Tcode IW24
Section

PM-03 General Maintenance

Processing
PM-03-02 – Order Processing
 Damage Related Process Maintenance Flow

Plant PM Planning PM Work Center

Problem , Error 3 Task Planning.
4 PM Order
Malfunction,Request,
Activity
PM Order creation 5
Execution plang. Execution
•Who •Material
1 •When, How long
PM Notification Withdrawals
•What work steps
•What Requesting 2 •Account Assign.
•Utilities
•When a Task •Work steps
•Where •Resources

•Technical
Technical Info.
7 6
•Breakdown
Information Completion
•Causes,Activities
•Breakdown •Object affected Completion
Completion Confirmation
8 PM History
Maintenance Processing

PR creation Notification creation

PR release as per BDP
Tendering, PO
creation, GR at Order No
stores and required ?
transportation to
local storage as Yes
per MM, OLM
Order Creation
procedure

Material withdrawal Order Execution Work

Clearance/permits

Technical Completion

Order Settlement Notification Completion

Business Completion
Update technical history
Maintenance Activity Types In Orders
Maintenance Order Processing

Elements of Maintenance Order

For example: Order Type, Dates,Plant, Main object,
Order header Priority, Description, Maintenance Activity type

For example:- Functional Locations, Equipment

Object list Maintenance Notifications, Assemblies.

For example: Work Center, Control key, Descriptions

Operation Standard time, Activity type,

Material list For example: Material, Quantity, Storage Location

Production resources/tools

Settlement Rule

Costs
(Estimated / Planned / Actual)
Operations

Operations

List of operations

Operation Work Center Control key Description Activity Type

0010 MECH PM01 Oil change MAINT

0020 MECH PM01 Drain oil MAINT

0030 MECH PM01 Change oil filter

0040 MECH PM01 Add new oil

0050 ELEC PM01 Check cable

Stock Material Process Flow

Component
assignment

Material
Reservation

Availability
Order
check
Release
May

Printing

Automatic
availability
check May Goods
issue
Order Release

Effects of Order Release:

Reservation effective,
can be withdrawn

Shop Papers can be printed

Confirmation possible

Goods movement possible

Order Debits after Settlement

Order Execution Other Postings

Maintenance
Order

• Completion • Invoice receipts

Confirmations • Controlling
• Material Postings,
Withdrawals

Act. Costs > 0

Act. Costs > 0
Order Settlement

After settlement actual

Cost on the Order is
“ZERO”
Order Processing Summary

Plant Maintenance Controlling

Confirmation
Completion

Completion

Completion
(Business)
Settlement
Execution

Technical
Planning

Release

Order
Time

• Order not Modifiable • Postings cannot

• Postings can be be
made to the Order
Made to Order
PM Order Costing

PM Order Costs
Internal activity Internal processing:- Rs. 500
Op. 10:- 3 hrs
Op. 20:- 1 hr
External Services:- Rs. 150
External processing
Op. 30:- EXTERN 1 hr.
Warehouse Issue:- Rs. 300
Warehouse issue
2 pcs Material ABC

Total:- Rs. 950

 PM Order settlement

COST CENTER
(MAINT) COST
Activities :- PM Order
Mech. activity. Equipment 4011
CENTRE
Elect. activity.
Operation 010: 10h
Workcenter Mech

WorkCenter
'Mech' Operation 020: 3h
Workcenter Electrical
Work Center
Electrical

Material
Receiver
Settlement: - Fixed Amount OR percentage Distribution
Maintenance Processing Cycle
Action Logs
Order Hierarchy

If maintenance order consists of several independent steps whose

costs should be separated, order hierarchy can be used.

All sub-orders should be completed before a main order can be

completed.
Movement Types in PM

101 – Goods Receipt from Vendor

102 – Reversal of 101

261 – Goods Issue from Warehouse to Maintenance Orders

262 – Reversal of 261

201 – Goods from Warehouse to Cost Center

511 – Reversal of 201.

541 – Goods to Vendor for Refurbishment

303 – Transfer Posting to another plant / storage location

305 – Receive material from another plant

Understanding the Transaction

PM-03-03-02 Order Processing

 Create PM Create Order Processing Tcode IW31(Normal)
 Create PM Create Order Processing Tcode IW31(Refurbishment)
 Create PM Create PM Sub Order using Tcode IW36
 Goods Withdrawal using Tcode MB1A
 Completion Confirmation using Tcode Tcode IW41
 Overall Completion Confirmation using Tcode IW42
Section

PM-04 Refurbishment Cycle

PM-04-01 – Refurbishment Cycle
Refurbishment Processing

Types of Refurbishment

Refurbishment Order

OEM Repairs Central Workshop

Refurbishment cycle - OEM

Uninstall
Create N9 CreatePM60 type of
Equipment .
Notification Maintenance Order
install at Vendors FL

Create Batch and

And send to stores with Create PR/PO
movement type 202
Refurbishment Cycle .. contd

Send Equipment Send equipment

To vendor Receive Equipment (GR) To Function location
movement type 541 Movement type 261

Complete Order
Settle & Close Order
Refurbishment cycle - Workshop

Change Plant ,
Uninstall And send to stores with
Work Center and planner group.
Equipment movement type 202
Retain Cost Center of Asset

Transfer Posing from

Asset to Workshop. To Central Workshop
Movement type 303/305
 Refurbishment Cycle .. contd

Complete the order.

Create Refurbishment
Replace defective parts Settle to Asset
Order
Cost Center

Transfer Posting from

To Asset
Workshop to Asset
 Refurbishment Cycle .. contd

Send Equipment
From stores to F. Install Equipment
Movement type 201
 Refurbishment cycle for repair at OEM/External
Maintenance Dismantle
Create
order for Create a equipment & Transferring
Notification
repair ‘PM60’ BATCH install at Repair to Stores
‘N9’
IW31 MSC1N Location MB1A (202)
IH01or IW21
IE02

Release Create
Send to Release Create Purchase
Purchase Purchase
vendor Purchase order Order
Requisition Requisition
MB1B(541) ME28 ME21N
ME54 ME51N

Create & Maintenance

Vendor to Stores to Change Equipment
release order
Company after Functional data & Install at
Service entry Completion
repair location original location
sheet IW32 / MIGO /
MB1B (542) MB1A (201) IE02
ML81N IW41 / TECO

XXX Transaction code

Complete
Notification
IW22

323
Understanding the Transaction

PM-03-04-01
 Create PM Create Order Processing Tcode IW31(Refurbishment)
 Goods Back to Stores using Tcode MB1A
 Goods Transfer Posting Tcode MB1B
 Stock Overview Tcode MMBE
 Completion Confirmation using Tcode Tcode IW41
 Overall Completion Confirmation using Tcode IW42
Section

PM-05 Work Clearance

Management
PM-05-01 – WCM
WCM

Reasons for Work Clearance Management : -

 Maintenance Crews require safety measures.

 Maintenance activity need to be performed while the systems are
operational
 Work related measure which require special health and safety measure
ie. Controlling and monitoring lockout and tagout of various
equipments.
WCM and Maintenance Process

WCM
WCM Architecture

The work clearance application represents the safety certificate especially for
lockout/tagout.
In Plant, we will use WCA for getting prior approval to carry out any maintenance
job that requires WCM.
Two types of WCA :
Hot job/Cold Job - Do not require WCD
Tagout - Requires WCD
The work clearance document describes lockout/tagout. It contains a list of the
technical objects in a technical system to be tagged or monitored. It controls the
physical blocking and signposting of the technical objects affected. It also
contains a detailed description of how the system should be isolated.
WCM Architecture
WCM Model
WCM Permit

WCM type permit to be attached to the order for initiating WCM

WCA contains approvals to be granted for job execution

WCD contains approvals to be granted to ensure safe working

conditions.
Phases and Roles

Phases / Roles
WCM Objects Phase/Proces Carried out by
s
Order Create Order Order Creator

Application for
Work Clearance executing the Order Creator
Application above order

Work Clearance Specify Objects

Order Creator
Document Containing Tagout

Work Clearance
Approve Work Competent Authority
Application

Various concerened
Work Clearance Approve / Perform agencies like control
Document Tagout room, electrical,
mechanical, safety
WCM Process

1. A Maintenance Executives (maintenance in-charge, sectional heads) creates a

maintenance Order

2. If the job requires work clearance Maintenance Executives creates the WCA for
the order and requests the approval from competent authority to perform the job.

3. He also creates / copies from a template a Work Clearance Document. The WCD
contains details the tagging/un-tagging conditions of all the equipment / functional
locations / any other object (even w/o master data) which need to be tagged to
carry out the above maintenance work.

4. WCA created above is approved by the competent authority giving the clearance
for executing the maintenance activity.

5. At the time of actual execution, the tag out / lockout of the equipment mentioned
in the WCD is approved by various concerned agencies like control room,
electrical, mechanical, safety and their status is maintained in the system.

6. Any conflict in the status of any of the specified equipment / functional location
is prompted by the system.
WCM Process

Phases / Roles
WCM Objects Phase/Proces Carried out by
s
Order (after Maintenance In-
Labour Release
tagging) charge / Executor

Confirm that work

Maintenance
Order in the order is
Executive
comp

Work Clearance
Closed Approving authority
Application

Work Clearance Perform Un-

Document Tagging

Order Technical complete

Maintenance Incharge
the order
WCM Process

6. When Tagging has been performed, the maintenance In charge can release the
order ( Labor release). Order release can take place independently of this.

7. After the work has been carried out and tag-out/log-out is no longer required, the
maintenance executive sets the status Work complete for the order. Technical
completion is possible only on WCD completion.
WCA Status Sequence
WCD Structure
WCD

Enter all technical objects that are to be processed using tag-out /

logout. The WCD may include equipment, functional locations and
items not maintained in the R3 system.

The WCD contains the detailed description of how the system should
be isolated.

The WCD controls the physical isolation and placing of tags on

affected technical objects (items).
WCD

The WCD template is used as a copy model when creating work

clearance documents.The work clearance document template itself
cannot be used to perform lockout/tag-out. Therefore, it cannot be
tagged/untagged or assigned. With template, the work clearance
documents for complex structures of technical systems do not
always have to be recreated.

The operational cycle is divided into the following operational

phases:
 Tagging
 Temporary un-tagging
 Un-tagging

In the operational cycle, the items in an operational work clearance

document run through several statuses for each operational phase in
a specific sequence.
WCD Items
Operational Cycle
Operation Group

The WCD items defines the technical objects which need isolation for
lockout/tagout.

Operation condition gives the detailed description of conditions /

parameters for technical object (open /closed)

Each operation condition is valid for tagging / untagging.

Operational group is a logical grouping of operation conditions

designed to minimize the conflict.

For a technical object to be tagged / untagged, the system checks if

this objects is already a reference object in a processed Operational
WCD. A technical object cannot have different operational
conditions.
Operation Protection/Conflict Management

Protection which ensures that a technical object, which is managed as an item in an

operational work clearance document, can only be tagged/untagged from certain
Operation WCDs.

The operational protection can be used to protect the un-tagging of a position of

the operational work clearance document against other operational work clearance
documents.

The operational protection can be used to create protected areas. A protected area
is defined using the following criteria:

Operational protection of items in operational work clearance documents that

represent technical objects

Direct linking of operational work clearance documents using superior work

clearance applications

A technical object with operational protection can be tagged/untagged within the

protected area. However, it is not possible to tag/un-tag the technical object
outside of the protected area.
Section

PM-06 Calibration Cycle

PM-06-01 – Calibration Cycle
Calibration Processing Cycle

Calibration Create Measuring Point

plan

Classification
Calibration Order
Assign to Measuring Point List

Enter Readings
Assign Measuring
List
to task List
 Calibration Cycle

 Create Measuring point of Category ‘C’ for each calibration value.

 Assign Measurement position for calibration value.
 Assign Measuring Point to Task list.
 Create maintenance plan wrt to calibration equipment and task list.
 Schedule the maintenance plan and release order
 Enter the measurement reading for the equipment

Eg for a Diff pressure flow meter with pressure and temperature

corrections and calibration check for 0,25,50,75 and 100% values, 5
measuring points for each parameter ie. totally 15 measuring point
exists for the meter.
Understanding the Transaction

PM-03-06-Calibration cycle
 Create measuring point IK01.
 Create Measuring reading t entry list IK31.
 Create Equipment task list IA01
 Create measuring plan IP41
 Release Order IW32.
 Enter measuring reading IK34
Section

PM-07 PMIS
PM-07-01 – PMIS
PM Information system

Maintenance Process Reporting and Analysis

Work
Order Graphic
Noti- TOOLBOX
fication
ABC analysis

Equip- Classification
ment
Noti-
fication
Apply
H Info Database
i Info Database
s
t Objects Downtime
o
r
y MTBR Costs
 Plant Maintenance Reports

 Analysis of Maintenance Order Costs as per internal labor , material

, services cost.
 Monitoring of Maintenance order compliance / back logs for
Planned / unplanned / emergency order.
 Break down analysis as per cause , damage and part failure.
 Manufacturer wise analysis of Equipment maintenance.
 Material Consumption report for Equipment.
 Mean time to repair and mean time between failure reports for
Equipments.
 Calibration test reports for Instruments.
 Measuring value parameters for equipment
Understanding the Transaction

PM-03-07-PMIS
 Manufacturer Analysis using Tcode MCI2
 Planner Group Analysis MCI4
 Object Analysis using Tcode MCI6
 Cost Analysis using Tcode MCI8
 Mean Time Between Repair using Tcode MCJB/MCJC
Thank You