The SAP Plant Maintenance (SAP PM) application component gives an organization a tool for performing all maintenance tasks. Because all maintenance tasks are interrelated, this SAP modules PM is tightly integrated with other modules such as Production Planning, Material Management, and Sales and Distribution.
You can automate repairs and streamline maintenance requests in an organization using SAP PM. It enables you to log issues in the SAP system, organize labor and material operations, and track and settle costs.
You can discover, document, and manage problems in a company, as well as do enterprise asset management for any essential assets.
Plant Maintenance includes the following submodules to help with these tasks:
- Technical object and equipment master record management.
- Maintenance job planning.
- Under maintenance order management, you may manage workflow notifications and work orders.
Key Functions of SAP modules PM
Following activities are performed under Plant Maintenance −
Inspection
Inspection is carried out to determine the current state of a technological system.
Preventive Maintenance
Preventive maintenance is performed to keep the technological system running smoothly. It comprises actions such as maintenance planning and job scheduling for technological items.
Repair
All procedures that can be taken to restore the optimal state are included in the repair. Many planning stages, including as work scheduling, resource planning, and initial costing, can be used to carry out the repair process. You can react quickly in the case of a damage event that causes a production stoppage. To decrease downtime, you can prepare needed purchase requisitions and processed work orders.
Organizational Structure of SAP modules PM
The overview of SAP PM would be incomplete without information on the organisational structure used by this module. The organisational structure of every firm that uses the SAP PM module is segmented into the following format, utilising the same hierarchical level as shown below.
When a customer wishes to install SAP PM for their company, they must first pick which plant they want to do it for. This is because they may have three or four plants in different locations or cities, and the management chooses which plant to install SAP PM for. After this choice is reached, the project will be kicked off and implemented following the ASAP process.
SAP modules PM (Plant maintenance) Business Processes
Forecast
Detailed study of types of machinery and budgeting for the same on maintenance cost which includes:
- Internal labour
- External labour
- Service contracts
- Spares
- Capital equipment expenses, etc
in order to do the entire maintenance function Machine preventative maintenance will be planned annually based on machine manufacturer recommendations and maintenance crew expertise.
Maintenance planning
Preventive maintenance schedules, such as daily, weekly, half-annual, and yearly, are meticulously planned. Also, capacity planning.
Execution on planned maintenance
According to the planned maintenance schedule, scheduled maintenance processes are turned into preventative maintenance work orders, which are then carried out as anticipated.
Execution on unplanned maintenance
Unplanned maintenance entails the creation of work orders for machine stoppages, as well as the execution of these orders.
Report generation/capturing
Relevant data & reports can be captured from the system like:
- Breakdown hours
- Equipment history
- Order status
- Cost
- Labour hours
- Spares consumption
- etc.
SAP PM integration with other modules
Work Centers
Work centres are groups of employees that do maintenance tasks in the Plant Maintenance department. Work centres can be of several sorts, such as mechanical, electrical, or instrumentation. So, here is how the HR module is integrated. Each labour centre will have varied pay or hourly rates, which is nothing more than a cost. So that’s how the CO module is integrated.
Bill of Materials (BOM)
This is a bill of material, which indicates that materials are utilised in equipments, which then leads to a list of things stored in the material master, which is nothing more than MM module integration. At regular periods, some testing equipment or devices must be calibrated. Calibration orders are used to do this. The SAP PM and QM modules are linked together in this way. A budget is given from a finance team for typical investment or capital orders (maintenance orders). This is the FI module’s integration. Equipment is regarded a work centre in the production area (work centres are only considered work centres in the production area; technical items are considered work centres in the PM), and their appropriate work centre information will be preserved in equipment master data. This is a SAP PP module integration.
Other SAP modules, such as Material Management, Production Planning, Personnel Management, and Sales and Distribution, can be integrated with SAP PM. These modules are used to store current data according to Plant Maintenance requirements, and they are started automatically to keep the current data in the system.
Following are the key modules in which integration is performed with Plant Maintenance −
- Material Management
- Sales and Distribution
- Personnel Management
- Controlling
- Production Planning
The following figure depicts a work order notification process and shows how it is executed under Plant Maintenance.
The key steps involved are −
- Notification
- Newly Created Work Order
- Creation of Purchase request for work orders
- Purchase Order created and parts Received
- Parts issues to Work Order
- Approval and Planning of Work Order
- Scheduling and Releasing Work Order
- Work Order Execution
- Closing a Work Order
MM-PM Integration
The following are some of the MM-PM integration features: 1) Purchase requisitions may be generated from plant maintenance orders for non-stock commodities. The Purchase Order is created from the PR. When products are received, the cost is immediately charged to the plant maintenance order.
2) For stock material requirements, a reserve may be made from a plant maintenance order, and the material can be provided against the reservation.
3) Similar to materials, PRs for services can be generated from a plant maintenance order.
BOM – Bill Of Material – is another integration.
With Equipment BOM, you may produce a list of materials from which equipment is made, or, in other words, you can list the spare parts that you might need during equipment repair.
FICO-MM-PM Integration
Collaboration with MM:
- Batch Managed Material as Equipment Material Master Record
- Goods and Reservations Maintenance Order is issued.
- Material valuation class/types for materials used in refurbishing as equipment
- Press Release Triggering from a Maintenance Order
Connecting to FICO:
- Numbering of assets and sub-assets in the Equipment Master Data
- Activity-based pricing for operations carried out under a Maintenance Order
- Accrued expenses in Maintenance Orders are settled to the G/L Account, Cost Center, Asset, and so on.
SAP PM module jobs
SAP PM Responsibilities
- Assist with the implementation and adoption of SAP PM in a company.
- Conduct a thorough analysis of the market model’s developing parameters and incorporate those findings.
- Operating system solutions that are relevant; Client specs are defined, analysed, authenticated, and monitored.
- PM Blueprinting for the Company
- Organize seminars to meet the demands of the firm.
- From the perspective of SAP PM, sorting the company’s technological base
- PM should be planned, optimised, updated, and evaluated.
- Interpreting system requirements, solution architecture, system configurations, system monitoring, user training, file transfer, document management, and system integration are all responsibilities.
- Create a methodology that meets the client’s needs, procedures, and expectations in the market.
- Changes to meet the needs of the users
- The construction plant’s modification and development comply to an appropriate SAP PM technique and the buyer’s precise satisfaction.
- Recognize issues and challenges, and place an emphasis on solutions.
- PM Supplies, Arrangement, Access Code, BOM, Repair Job Sheet, Evaluation Point, Counters, PM Task Centers, and Maintenance Plans are all part of the overall organizational master data arrangement.
- Assist in defect detection by acting as a client link: examine, comprehend, and correct software flaws
- If necessary, handle adjustments or vital transit for difficulties.
- Report on the technical structure, working example, and outcomes of the Degradation Mechanism, Restorative Improvement Process, Productivity Oriented Predictive Repair Framework, Timeframe Based Protective Maintenance Process, Revamp Process, Advanced Service Management Process, and Coordinated Process implementations.
- PP, MM, CO, and QM modules automate market processes.
- Identify and suggest changes to corporate processes and programs that are thorough.
- Advisory services for both new implementations and existing sustainment systems are available.
- Serve as a link between corporate functions and operational personnel.
- As needed, provide ad hoc counseling and client assistance.
- Focus on self-direction and self-governance; can act as a mentor to more junior trainees.
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