Workshop

SAP Plant Maintenance

SAP S/4 HANA Implementation
CONTENTS

• Overview
• Organization Structure
• Master Data
• Maintenance Process
SAP S/4 Hana Solution Map
• Cost Center
• People • Asset Master Data Mgt. Reporting
Administration • Account Payable (AP) • Cost Settlement &
• People Development • Account Receivable Allocation
(AR) • Profitability
• Chart of Account Analysis
• Tax

Human Resource Finance Controlling

(HR) (FI) (CO)
• Operator Timesheet • Asset
Report & nt n Under
et tio
ss ipme niza Constructio

• Product
Costing
• Mechanic WO • A u o
Confirmation Eq nchr n
Sy
• WBS
Assignmen
• P t
a Project Systems Production Planning
Plant Maintenance Fu rts &
(PM) Co el (PS) (PP)
• Unit Master Data on nsu • Project Definition & Monitoring • Production Planning
mp
Mgt. t i • Cost Collection (for Pre- • Production Order
• Work Order Production) Management
l
Management • WBS Cost Monitoring Coa
• Timesheet Unit B& t
• O ceip
Re
• Parts Inventory
Mgt.
• Coal Inventory Sales & Distribution
Mgt. Material Management • Coal Issuing
(SD) • Sales Order
• Purchasing (MM) Processing
Process • Billing Processing

Page 3
SAP Plant Maintenance
What is SAP PM ?
SAP Plant Maintenance (SAP PM) is one of module in SAP ERP that manages all maintenance
activities in an organization. Plant Maintenance module consists of key activities to include
inspection, notifications, corrective and preventive maintenance, repairs, and other measures to maintain
an ideal technical object.

SAP PM Integration CO
FI
Through integration with other modules
(for example, Materials Management,
Production, Sales and Distribution,
Personnel Management, Finance PS
and Controlling, and Project System)
the data is always kept current and
MM PM
processes that are necessary for Plant
Maintenance and Customer Service are
automatically triggered in other areas HR
(for example, a purchase requisition for
non-stock material in the Materials SD
PP
Management/Purchasing area).

Page 4
Who will get the benefit from SAP PM?
Maintenance and operations managers, who can use PM to obtain metrics on
equipment performance or maintenance deployments. They can use PM to improve
maintenance decision-making by running reports on work that's planned, in
process, or completed.

Production workers and equipment users, who can use PM to manage

maintenance issues more promptly and effectively.

Maintenance personnel and technicians, who can use PM to improve work

processes and efficiency. For example, technicians can use PM to review
maintenance records.

Purchasing departments, who can use PM to manage and execute the purchase
of non-stock spare parts and services needed for maintenance work.

Finance departments, who can use PM for monitoring maintenance cost

accurate and up-to-date data based on equipment maintenance history.

Page 5
SAP PM Main Scope in The Unit Lifecycle
Production Plan
PLAN & ACQUIRE

XX BCM
XX TON

Unit Realization *
Asset
Investment Budgeting (Procure to
Acquisition
Plan Pay)

Running Hour
Updating

Asset Depreciation
OPERATE & MANTAIN

Parts Mgt.
Maintenance Unit Maintenance Unit
Execution Operation Plan Registration
Service Mgt

Master Data
Fuel Management
Consumptio
n

Maintenance Operating
Owning Cost
Cost Cost
DISPOSE

Unit Unit
Unit Lifetime
Replacemen Retirement
Upgrade
t Analysis (Disposal)
Main PM Scope

Page 6
SAP PM Business Process Phase
Organization Structure

Master Data Work

Work Planning Work Execution Work Completion
Management Identification

Master Data Work Identification Work Planning activities Work Execution Work Completion
Management to cater activities for ensuring and for ensuring Work activities for ensuring activities for ensuring
all required data providing the information Order Maintenance is Work Order is being completion of WO
needed from Operation of Plan Maintenance Work fully prepared before executed and all status & requirement
Point of View execution relevant data is
updated

• Manage Equipment • Create Maintenance Plan • Create Work Order• Consume Part & Material • Complete Work Order
• Manage Functional • Update Measuring Point • Plan Activity, Parts &
• Procure Non-Stock • Settle Cost to Actual
Location • Generate Maintenance Material, and Resource
Material or External Receiver Cost Object
• Create Measuring Point Schedule • Approve Work Order Service
• Manage Bill of Material • Generate PM Notification • Reserve Budget • Goods Receipt Non-Stock
or Work Order (Commit) Material or Ext. Service
• Manage Maintenance
Strategy • Create Corrective • Reserve Material • Consume Budget
Notification (Actual)
• Manage Task List • Generate PR for Non-
• Confirm Work Order
Stock Material or Ext.
• Manage Catalog Profile
Service Activity
• Consume Fuel
Reporting & Performance Analysis
(Operation)

Page 7
CONTENTS

• Overview
• Organization Structure
• Master Data
• Maintenance Process
SAP PM Organization Structure
The fundamental aspect should define before configure SAP PM process is the PM Organization Structure, which it usually
represent the client maintenance organization too. The SAP PM Organization Structure (Enterprise Structure) will use to
identify the responsible organization for any PM transactions, authorization restriction, grouping on reporting and
performance analysis.
Company • Company Code representing the legal entity or organization which
Code has own financial statements and balance sheets. Commonly,
company code use to represent company it self.
• Planning Plant representing the plant in which the maintenance tasks
Planning for the object are planned and prepared. Maintenance Planner
Plant Groups work at the maintenance planning plant to plan and prepare
the maintenance tasks for the maintenance plants that are assigned to
the maintenance planning plant.
Planner
Group

Maintenanc • Maintenance Plant representing the plant in which the technical

object was installed or operated. Also being plant organization who
e Plant
execute the maintenance tasks.
• Maintenance Work Center is a core organization master data
Work defined for performing maintenance work in the operation of a work
order. Work Center can represent machine or group of people.
Center

Page 9
Maintenance Planning Plant
Maintenance Planning Plant representing the plant in which the maintenance tasks for the object are planned and
prepared. There are some type of Maintenance Planning Plant
1. Centralized
Centralized mean all of the Maintenance Plant within the company code are under single Maintenance Planning Plant.
2. Decentralized
Decentralized mean every maintenance plant assigned to 1 maintenance planning plant.
3. Partially Centralized
Partially centralized mean there is some of maintenance plant assigned to 1 maintenance planning plant and another are
assigned one by one
Decentralize Centralized
d
Company Code Company Code

Planning Plant Planning Plant Planning Plant Planning Plant

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance

Plant Plant Plant Plant Plant Plant

The Maintenance plant is the plant where the technical objects are physically present in the plant and Maintenance
Activities are carried out in this area.
Page 10
Planner Group
Planner group are the groups of employees responsible for planning and processing maintenance task and
maintenance task list data in a plant.

Propose:
The client has several groups or section to manage maintenance
activities which classified based on type of technical object
P01 P02 P03 G01

PLANT TIRE REMA GA

Who manage Who manage N
Who manage Who manage
Fleets Tires of Fleet Major Component supporting
eqp.

Page 11
CONTENTS

• Overview
• Organization Structure
• Master Data
• Maintenance Process
Work Center
The main 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 .

SAMPLE
Maintenance
Plant The client has several group which classified based on area of
competency

Plant – 1001
Kalimantan
Work Center Work Center

Group of Group of PLT-1001 TIR-1001 RMN-1001

Employee Employee
• Name A • Name M
• Name B • Name N
• Name C • Name O
• Name D • Name P
• Name E • Name Q
Plant Site Tire Site Reman Site

* Link with HR Personnel

Number

Page 13
Equipment in Mining Industry
From Mining Industry perspective, equipment
master data will use to cover all main machine/unit Mining Supporting
for core production activities, and supporting Equipment

machine to support secondary mining activities.

Mining Main Equipment

(Heavy Equipment)

Crusher, Conveyor, &

Jetty Facilities

Boat and Barge

Page 14
Equipment
Equipment SAP PM has a standard feature to maintain multilevel
of equipment, the equipment hierarchy can use to
define the Superior Equipment and Sub Equipment.
Superior Equipment Main Equipment
A superior piece of equipment is a complex system Superior
Equipment
that is made up of several individual pieces of
equipment.
Equipment Usage Period
Install & Dismantle Process

Equipment is known as an The system creates a usage period list, in which it Sub Equipment

individual object in the makes one entry per equipment usage period, for Major
system that is maintained Component
each piece of equipment. This list forms part of the
independently it can be
defined for :
equipment history: when equipment has been
installed and where the position has been placed for
• Means of Production
its superior equipment.
• Means of Transport Equipment Model Number Serial Number Position Installed Date
• Vehicles
• Test Equipment 99000000000011 BGX10R TRSDT088-0260-3 0010 20.01.2016 18:00
• Production resource/ tools TMLHEX125-0480-
• System, system parts 99000000000012 BGX10R 0020 19.12.2015 07:00
3
• Customer devices
• Building property 98000000000001 LP-100.1 T02GT-SN01 1011 01.01.2015 08:00
98000000000002 LP-100.1 T02GT-SN02 1012 01.01.2015 08:00

Page 15
Define Equipment Category
Equipment Categories should be minimal and should represent
types of objects that are fundamentally different. It use for
distinguishing individual technical objects according to their use.

Equipme Description Number Range ABC Indicator

nt
Category O Owning
Main Equipment External Number
H
(Heavy Equipment) R Rental Internal
K Supporting Equipment External Number

M Machineries External Number

C Major Component 99000000000001 Equipment Owning Indicator are the indicator

to show the ownership of the unit, it can help
T Tire 98000000000001
the user to decide either the maintenance plan
External Number or assignment for the unit
P Tools

G GA Equipment 96000000000001

Page 16
Define Naming of Equipment Number (1/2)
An equipment number is one of fundamental identification of equipment, end user can be easily to identify
unit in the system by common familiar numbering, this standard naming can be configured in the system per
equipment category.
Main Production Equipment Naming
Rental
Unit Type Unit Number Unit Class Identificatio
n

A A N N N N N N N N A

Excavator Komatsu PC Dump Truck Hino

DT025 – 0260 –
200 EX010 – 0200 – 1 FM260TI
2X
Status Owning Status Rental

*For equipment category H,

K, M & P
Page 17
Define Naming of Equipment Number (2/2)
An equipment number is one of fundamental identification of equipment, end user can be easily to identify
unit in the system by common familiar numbering, this standard naming can be configured in the system per
equipment category.
GA Equipment Naming
External Number
Vehicle License Plate

Mobil Honda
B 1234 GMA
HRV
A A N N N N A A A
*For equipment
category K

GA Equipment Naming
Internal Number
Running Internal Number

AC
Computer
Panasonic
______________ 9600000000000 9600000000000
1 2
*For equipment category G, T &
C
Page 18
Define Equipment Object Type (1/2)
Object Types on the other hand represent the type of equipment in greater detail. It is further distinguish
Equipment based on Type/make. And from system point of view, the object type will use to identify whether
an equipment will be threat as fleet.
Type of Technical Object Type of Technical Object Type of Technical Object Type of Technical Object
HE-AD Articul. Dump HE-TB Tug Boat PE-CT Common Tools PE-MM Milling Machine
Truck
HE- Track Type Loader PE-CV Conveyor PE-MT Motor Electric
HE-CP Compactor/Roller
TTL
PE- Cosway PE-OHC Overhead Crane
HE-DL Dolly HE-VS Vessel
CW
PE- Port Dermaga PE-RF Reclaim Feeder
HE- Drilling Machine HE- Backhoe Loader
DM WB DM
PE-ST Port Stockpile
HE-DT Dump Truck HE- Wheel Type PE-GB Gear Box Area
WL Loader
PE-GS Genset Port SE-BT Boat
HE-DZ Bulldozer
PE-BM Bor Machine
Facility
SE-CM Air Compressor
HE-EX Hydraulic PE-JC Jeeb Crane
PE-BR Breaker
Excavator
SE-COMM Communication
HE- Motor Grader PE-BW Break Water PE-JTY Port Jetty Facili
GD
PE-KL Kidney lube SE-CT Crane Truck
PE-CP Centrifugal Pump
HE- Off Highway Truck
HD SE-FL Fork Lift
PE-CR Crusher PE-LM Latch Machine
HE-PM Prime Mover
Page 19
Define Equipment Object Type (2/2)
Object Types on the other hand represent the type of equipment in greater detail. It is further distinguish
Equipment based on Type/make. And from system point of view, the object type will use to identify whether
an equipment will be threat as fleet.
Type of Technical Object Type of Technical Object Type of Technical Object
SE-FS Fuel Skid SE- Motor Cycle SE-WM Welding Machine
MO
SE-FT Fuel Truck SE-WP Water Pump
SE-MP Mining Pump
SE-GS Genset SE-WT Water Truck
SE-MS Mobile Support
SE-GT Garbage Truck CO- Major
SE-MT Mega Tower Lamp MAC Component
SE-LB Low Boy CO-TIR Tire
SE-PT Plant Tools
SE-LS Lube Skid GE-AC Air Conditioning
SE-SL Simulator OHT
SE-LT Lubrication Truck GE-BUL Building Facilities
SE-ST Service Truck
SE-LV Light Vehicle GE-INF Infrastructure
SE-TH Tire Handler
SE-MC Mobile Crane
SE-TL Tower Lamp
SE-MH Man Haul
SE- Weighbridge
WB
Page 20
Equipment User Status Definition
Equipment User Status gives information of current status of equipment, controlling restricted business
transaction and proper approval. Equipment user status can be defined per Equipment Category.

Usage of Equipment User Status

Apart from giving the detailed information about the business document, User statuses are giving different
control on the business perspective.
• Giving Control by giving Proper Information
• Giving Control on the Business by restricting the Transactions
• Giving Control on the Business by having the Proper Approval

Page 21
Classification & Characteristic
Classification & SAP has provide characteristic master data to maintain specific data related to
equipment which not put in the standard fields. User can grouping some
Characteristic characteristics data into classification and assign it into Equipment Master Data.

Create Assign to Input Data in

Characteristic Classification Equipment
Horse Power Unit Specification

Number of Cylinder Unit General

Information EX010-
Classification and Hydraulic Motor
0200-1
Characteristic are Horse Power 116 KWH
tools in SAP for Fuel Tank Capacity Number of
6
classifying an Number of Shoes
Cylinder
equipment based on Hydraulic Motor 2
special features or Fuel Tank Capacity 400 L
External Location
characteristic such as
Number of Shoes 45
capacity, functionality Personal In Charge
and location External Location Jakarta
Estimate for
Disposal Personal In Charge Arnold
Estimate for 31.12.202
Page 22
Disposal 5
Functional Location Definition (1/2)
The Functional Location is an master data of organizational unit in SAP PM, that has multi level and
hierarchical structure, also organized according to spatial, technical, or functional criteria. Functional
Location can also defined to represent the place at which a maintenance task should be performed.

ZONE AREA PIT

1 1
1 PIT 1

AREA
2
ZONE ZONE 1 ZONE 2 ZONE 3
2
AREA
3
AREA 1 AREA 2 AREA 3 AREA 4

Mining Area

Page 23
Functional Location Definition (2/2)
Level 1 (XXXX)
T100
(Plant)

Level 2 (XXXX-XXXX) (XXXX-XXXX)

T100-P001 T100-P002
(Pit)

Level 3 (XXXX-XXXX-XXXX) (XXXX-XXXX-XXXX) (XXXX-XXXX-XXXX) (XXXX-XXXX-XXXX)

T100-P001-Z001 T100-P001-Z002 T100-P002-Z001 T100-P002-Z002
(Zone)

(XXXX-XXXX-XXXX- (XXXX-XXXX-XXXX- (XXXX-XXXX-XXXX- (XXXX-XXXX-XXXX- (XXXX-XXXX-XXXX-

Level 4 XXXX) XXXX) XXXX) XXXX) XXXX)
T100-P001-Z001- T100-P001-Z002- T100-P002-Z001- T100-P002-Z001- T100-P002-Z002-
(Area) A001 A001 A001 A001 A001

Page 24
Bill of Material Definition
From maintenance point of view, the Bill of Material is part structured of technical
object. It has two main functions:
• Structuring of Object
An object should be structured as clearly as possible from a maintenance view.
• Spare Parts Planning in Order or Task List
If a bill of material is available for a maintenance object, this can be used
easily during the planning of a maintenance order or task list to plan spare
parts.

Parts in Order Parts in Task List

Structuring of Object
Planning Planning

Work Order Maintenance

YY Task List Planning
Package
Equipment
Engine
A1234
Bill of 250 HR
Engine A1234 Material
1 FAN-DX8 1 PC 500 HR Task List
2 CUM-9981 2 Set 1.000 HR 1 FAN-DX8 1 PC
2.000 HR
Construction 3
4
CHS-2214
ALT-2001
2 PC
1
2
3
CUM-9981
CHS-2214
2 Set

2 PC
SET
Type … ………… …
4
…
ALT-2001
…………
1
SET
…
Material : 000-A1023

Page 25
Measuring Point
Measuring Point
Measuring
Point

Non
Counter
Counter
Measuring point is the physical
and/or logical location which a
condition is describe and
measured.
• Hourmeter (HR) • PAP
• Kilometer (KM) • Cylinder Rating
Parameters can be mapped
• Fuel (L) • Filter Cut
under Measuring Point:
- Running Hour • Oil (L) • Magnetic Plug
- Mileage (Kilometer)
- Etc.

Page 26
 Catalog Profile
Catalog Profile Catalog profiles have sub class of code groups which will group the codes as per their feature. All
the codes (Object Parts, Damage, and Cause) illustrate why an asset failed during production, what
is the cause for that failure, tasks to be performed & activities done for that failure. The use of
codes in a SAP system ensures a consistent way of documenting key aspects of the event
according to pre-defined categories.

Item to be
analyzed Catalogs Profile Master Data
• Object Parts ?
• Damage ? Object Parts Code Damage Code Cause Code
Catalog profile will group • Cause ?
A001 Engine Z001 Worn (Aus) X001 Mis-Assembly
different characteristics
of the notification which A002 Alternator Z002 Rusty (Berkarat) X002 Mis-Adjustment
will cater the needs of A003 Fuel Filter Z003 Leak (Bocor) X003 Mis-Maintenance
management to analyze
the company assets & to A004 Drive Belt Z004 Crack (Retak) X004 Mis-Operation
ascertain the decisions A005 Spark Plug Z005 Scratch (Tergores) X005 Life Time
accordingly
A006 Cord Spark Plug Z006 Dent (Penyok) X006 Environment

A007 Glow Plug Break X007 Bad Material

Z007
(Patah/Pecah)
Breakdown
Occurred

Page 27
Define Catalog Profile (1/2)
Z5001 (Plant Cause) ZA001 (Plant Activities) ZB001 (Plant Obejct Parts)
Code Description Code Description Code Description

5101 BF-Dirty Fuel / Bahan Bakar Kotor A101 Do Job B101 Brake Systems

5201 DD-Bad Design / Desain Salah A102 Waiting Parts B102 Bucket Body

5202 DD-Modified Component/Modifikasi A103 Waiting for Mechanic B103 Differential Fd

Kompone
5301 EN-Foreign Material / Benda Asing A104 Waiting Special Tools/Facilities B104 Drive Systems

5302 EN-High Altiude / Dataran Ketinggian A105 Accident & Assurance Process B105 Electrics & Ac Systems

5303 EN-High Temperatur Effect / Efek Suhu A106 Waiting for Doc & Decision of B106 Engine
Ti Management
A107 Waiting Out Site Repair B107 Frame/Chassis/Suspension/
5401 MD-Bad Material / Material Jelek
Steering

5402 MD-Material Fatique / Kelelahan Bahan A108 Waiting for Access B108 Hyd Systems

5501 OA-Abrasive Area / Wilayah Keausan A109 Waiting External Labour B109 Inspection
Tingg
A110 Rest & Change Shift B110 Maintenance/Services
5502 OA-Bad Infrastructure / Perlengkapan
Jel

Page 28
 Define Catalog Profile (2/2)
ZBPM0 (Preventive/Periodical ZC001 (General Damages) ZC002 (Tyre Damages)
Service)
Code Description Code Description
Code Description
C101 Abnormal Temperature C201 Smooth/Halus
B911 Periodical Service
C102 Corrosion/Rust
C202 Expose Ply/Ply Kelihatan
B912 Preventive Maintenance
C103 Crack/Bend/Stretch/Compressed C203 Center Wear/Keausan Tengah
B913 Project /Broken
C104 Difficult Brakes C204 Side Wear/Keausan Samping
B999 Other Planned
Service/Maintenance
C105 Difficult Steer C205 One Side Wear/Satu Keausan
Samping
C106 Dirt C206 Patchy Wear/Keausan Tidak Merata

C107 Elec Fault C207 Tread Chipping/Tread Terpotong

C108 Erractic Shifts C208 Tread Chunking/Tread Terangkat

C109 Excess Noise/Vibration C209 Tread Lifting/Tread Mengelupas

C110 Fire/Burnt/Melted Component C210 Tread Separation/Tread Terpisah

Page 29
Maintenance Strategy (1/2)

Maintenance It contains general scheduling information,

and can therefore be assigned to as many
Type of Planned Maintenance
Strategy maintenance task lists (PM task lists) and
Time Based Performance Condition Based
maintenance plans as required Based

Periodical Parameter

STRATEGY TIME-BASED PERFORMANCE-BASED

Name Prod. Equipment – Time Based Prod. Equipment – Hour Based

The Maintenance Strategy is Key Parameter • Key Date • Running hour

the core master data using • Factory Calendar
in Planned Maintenance
process, a maintenance Package Package Cycle Unit Package Cycle Unit
strategy defines the rules for M1 1 Months P1 250 HR
the sequence of planned
M2 2 Months P2 500 HR
maintenance work.
Y1 12 Months P3 1.000 HR

Y2 24 Months P4 2.000 HR

Page 30
Maintenance Strategy (2/2)

Here is some strategy that can

be use to developing strategy Maintenance
for equipment, the package of Strategy
maintenance are assigned by
their type
Periodical Preventive
Time Based
Maintenan Maintenanc
Maintenance
ce • e 4.000 HR
04 – Paket
• 06 – Paket 6.000 HR
• 08 – Paket 8.000 HR
• P0 – Paket 125 HR (Initial/ Pre • 10 – Paket 10.000
• M1 – Paket 1 Bulanan
Service) HR
• M2 – Paket 2 Bulanan
• P1 – Paket 250 HR • 12 – Paket 12.000
• M3 – Paket 3 Bulanan
• P2 – Paket 500 HR HR
• M4 – Paket 4 Bulanan
• P3 – Paket 1.000 HR • 14 – Paket 14.000
• M6 – Paket 6 Bulanan
• P4 – Paket 2.000 HR HR
• Y1 – Paket 1 Tahunan
• P5 – Paket 4.000 HR • 16 – Paket 16.000
• Y2 – Paket 2 Tahunan
HR
• Y3 – Paket 3 Tahunan
• 18 – Paket 18.000
• Y4 – Paket 4 Tahunan
HR
• Y6 – Paket 6 Tahunan
• 20 – Paket 20.000
HR
• 24 – Paket 24.000
HR
Page 31
Task List (1/2)
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. By using
general maintenance task lists, sequence of maintenance task can be define and
manage centrally.
SOURCE DEFINE STANDARD TASK LIST MASTER DATA

Maint. Planning
Strategy Plant Package Operation Activity Material No.

P1 • General Body Check • OIL-SAE40W

Maintenance task lists 250HR • Replace Hydraulic Oil
Initiative of Check Air System
describe a sequence of Improvement
individual maintenance P2 • General Body Check • OIL-SAE40W
Historical Data
activities which must be 500 HR •
•
Replace Hydraulic Oil
Replace Filter
• FILTER-ABC

repeatedly performed • Check Electric System

User Manual
within a company. Standard Task List • General Body Check • OIL-SAE40W
P3
1.000 HR • Replace Hydraulic Oil • FILTER-ABC
• Replace Filter • FUSE-XYZ
• Check Electric System • OIL-SAE70W
Planner Main Work • Replace Fuse
Group Center

Page 32
Task List (2/2)
Task List Item

Detail Pckg Description Cycle

Content P1 Preventive Maintenance 250 HR for Model A 250 HR

Prerequisites Task List Header Input Task List P2 Preventive Maintenance 500 HR for Model A 500 HR
Detail Information
P3 Preventive Maintenance 1.000 HR for Model A 1.000 HR
Maintenance P4 Preventive Maintenance 2.000 HR for Model A 2.000 HR
Strategy

Operation Activity
Planning Plant
Opr. Activity Description Person Duration
Planner Group 10 Operation Activity 1 for Model A 2 1,5 HR
Task List
Master Data 20 Operation Activity 2 for Model A 2 0,5 HR
Work Center
30 Operation Activity 3 for Model A 2 1 HR

Material Reqs.

Opr. Item Material Number Qty. UoM

30 1 ME-135-170 1 PC

30 2 ME-130-210 2 PC

Page 33
Maintenance Plan (1/2)
For each maintenance plan scheduling, the due date (planned date) of a maintenance plan to call
Maintenance Plan object will calculate based on the scheduling parameters and the maintenance cycles or
packages.
Fundamental Maintenance Scheduling
Standard Periodical Standard Parameter
Maintenance Maintenance
(Time-Based) (Performance-Based:
Sample : Sample : Running Hour)
Maintenance schedule for equipment calculate Maintenance schedule for equipment calculate
based on periodical 1 month and 3 months task list based on hour parameter packages (P1, P2, P3, P4)
packages
Maintenance planning is Plan
Measuring
used to avoid any Target Package Start Date Point
Date
equipment breakdown or Maintenanc (Key Date) P1 750 HR
production breakdown. It is e Plan M1 M3 500 HR
1 Jan ’20 Update by
used to represent 1 Jan
Current 24 Jan ‘20
Operation
inspection, Data ‘20
Actual
Measuremen
preventive maintenance t
and repairs for which P1 1000 HR
you plan time and scope of M1 M1 M3 20 HR 5 Feb ‘20
work in advance. Update by Per Day
1 Jan ‘20 1 Feb ‘20 1 Mar ‘20 1 Apr ‘20 Target Estimation
Utilization Daily
Start Plan Date Achievement
P1 1250 HR
Date
28 Feb ‘20

Page 34
Maintenance Plan (2/2)

Plan
P1 P2 P1 P3 P1

250 HR 500 HR 750 HR 1000 HR 1250 HR

Actual

P1 Next
P1 Schedule ? P2 P1 P1

300 HR 1400 HR 2000 HR 2100 HR 2800 HR

Next Schedule calculate based on existing planned parameter

Option 1

P1 P2 P1 P3 P1

300 HR 500 HR 750 HR 1000 HR 1250 HR

Next Schedule calculate based on last actual parameter executed

Option 2

P1 P2 P1 P3 P1

300 HR 550 HR 800 HR 1050 HR 1300 HR

Page 35
CONTENTS

• Overview
• Organization Structure
• Master Data
• Maintenance Process
Standard Maintenance Type Based on British Standard
Reference Run to Failure (RTF)
Only The reactive restore action to be
performed after failure occurred
Maintenance
The maintenance Only Useful in following situations
• The failure component is
activities which has been
unpredictable
planned before • The cost of failure is lower than
execution. performing PM/PDM
Planned Unplanned • The equipment failure priority is too
An order to bring failed
Maintenance Maintenance low
machine or facilitiy to a
safe and operationally An order performed
efficient condition RTF after breakdown
occurred during
Emergency Breakdown production

Redesigning machine or
Corrective activities that
Predictive Preventive facility to eliminate cause Improvement are not immediately and
Corrective
Maintenance A repetitive and Maintenance of maint., simplify maint. Maintenance delay will not affected Maintenance
(PDM) periodic maintenance (PM) task, and raise (IM) (CM)
production process
based on time cycle performance

Condition Statistical Time Based Parameter Design-out Engineering Deferred Remedial

Based Based Maintenance Based Maintenance Services Maintenance Maintenance

A modification, construction, Corrective activities

Depend on continuous Developed models A repetitive maintenance Shutdown removal, installation, or Shutdown Shutdown
performed without
monitoring to detect from data recording based on parameter Preventive rearrangement facilities may Improvement Corrective
interrupting production
sign of failure to predict failure achievement triggered by prod. purposes process

Page 37
Maintenance Notification
A Maintenance Notification is used to describe the condition of technical objects in the PM System, and request to the
operation / maintenance department to perform a necessary task that needs to be carried out and to document the
performed work.

Notification
Description
Type

B1 Breakdown Notification

M1 Periodical Notification

M2 Preventive Notification

M3 Inspection Notification

Z1 Equipment Movement

Page 38
Common Order Type in Mining Industry
The order type is a classification characteristic for orders. It consists of control information depend on business
requirements. Basically using different order types are meant to segregate maintenance job in different types so it can be
analyzed at individual level.
Group Code Description Cost Receiver

PM01 Periodical Service Cost Center (OPEX)

Preventive
Maintenance Preventive Maint. / Part
PM02 Cost Center (OPEX)
Replacement

PM11 Breakdown Maintenance Cost Center (OPEX)

Corrective
Maintenance
PM12 Emergency Maintenance Cost Center (OPEX)

Predictive
PM21 Predictive Maintenance Cost Center (OPEX)
Maintenance

PM31 General Overhaul Maintenance Cost Center (OPEX) / Asset (CAPEX)

Capitalized Order
PM32 Improvement Order Cost Center (OPEX) / Asset (CAPEX)

PM41 Part Refurbishment Order Material / Inventory

PM42 Part Fabrication Order Material / Inventory

Special Order
PM43 Tire Recondition Order Material / Inventory

PM51 Part Cannibalization Cost Center (OPEX)

Standing Order PM91 Fuel & Oil Consumption Cost Center (OPEX)

Page 39
Basic Preventive Maintenance on Mining Industry
Preventive maintenance are maintenance for scheduled Parts Component Replacement (PCR) as manufacturer standard
with planning due based on running hour from the equipment.

1 2 3 4 5
Create Update Generate
Generate Execute
Maintenance Measuring Maint.
Work Order Work Order
Plan Point Value Schedule

The Maint. Plan is Update Running System will When running hour The Maintenance
fundamental PM Hour to keep maint. automatically reach the task list Planner /Coordinator
data which bridging schedule updated. It generating package plan, system will release work order
Equipment to can be proceed by maintenance schedule, will automatically document and the
Maintenance Maintenance based on calculation of generating work order mechanic will execute
Strategy and Task Updating, Fuel existing running hour document to be the PM order
List Transaction, or to the task package executed.
Production Updating (parameter based).
Page 40
Preventive Maintenance Flow Process
Data Role
Master

Create
Create Create Task
Measuring
Equipment List
Point
Planner Role

Auto
Maint.

Create Auto Execute &

Generate Create Release Complete
Maintenance Generate Confirm
Maintenance Work Order Work Order Work Order
Plan Notification Work Order
Schedule
Operation

Update
Role

Measuring
Point
Logistic Role

Goods Issue
Material from
Stock to WO
Finance Role

Cost
Settlement

Page 41
Corrective Maintenance
Corrective Maintenance is a work order to accommodate unscheduled repair for equipment, the
main objective for this kind of maintenance are as fast as possible to restore its function.

Page 42
Corrective Maintenance Flow Process
Data Role
Master

Create
Create
Catalog
Equipment
Profile
Planner Role
Maint.

Execute &
Create Work Plan Material Release Complete
Confirm
Order & Resource Work Order Work Order
Work Order

Create
Notification
Operation
Role
Logistic Role

Goods Issue
Material from
Stock to WO
Finance Role

Cost
Settlement

Page 43
Predictive Maintenance
The Predictive Maintenance work order are a follow up maintenance action if any abnormalities has
been discovered before breakdown phase.

Normal
Condition

Monitoring
Unit

Equipment Performance Analysis Inspection

Critical
Condition

Maintenace
Unit

Page 44
Predictive Maintenance Flow Process
Data Role
Master

Create
Create
Measuring
Equipment
Point Rating
Planner Role
Maint.

Inspection Auto Execute &

Plan Material Release Complete
(Update Generate Confirm
& Resource Work Order Work Order
Meas. Point) Notification Work Order
Operation
Role
Logistic Role

Goods Issue
Material from
Stock to WO
Finance Role

Cost
Settlement

Page 45
Capitalized Order
Capitalized order is one of the Planned Maintenance Order, the different between the usual maintenance
order are all the cost from this type of work order will be adding to the equipment and will be amortized by
the end of the period.

Unit with addition of lifetime and new value of asset

Exchange the Part of
Equipment

Capitalized Order can use for General Overhaul to

extend of unit lifetime and as an Improvement to
modify the unit.

Page 46
Capitalized Maintenance Flow Process
Data Role
Master
Create
Create
Measuring
Equipment
Point
Planner Role
Maint.

Analyze Execute &

Create Release Complete
Performance Confirm
Work Order Work Order Work Order
Unit Work Order
Operation
Role
Logistic Role

Goods Issue
Material from
Stock to WO
Finance Role

Create Sub Cost

Asset Settlement

Page 47
High Level Flow Parts Consumption
LOGISTI
PLANT
Breakdow C
n
Occurred
Material
Breakdown
Reservatio
Notification
n

Transfer
Create
Stock Sloc
Work Order
to SLoc
Unit
Repaired Execute
Work Order

Post Actual
Complete
Part
Work Order
Consump.

Page 48
Special Order
Refurbishment Order to facilitate Tire Rotable Repair Order to facilitate tire
refurbishment process from dismantle until rotable for new tire, old tire and retread tire
the re-install to the equipment. from dismantle until re-installing to the
equipment.

Page 49
Cannibalization Order
Cannibalization order are prepared as a solution for tracing parts movement from non-operating
unit to operating unit.

Page 50
Standing Order (Fuel & Oil Consumption) (1/2)
Standing order have a function to allocating the cost from oil and fuel consumption from an
equipment, this WO status will be ‘Released’ as long as the equipment running.

Page 51
Standing Order (Fuel & Oil Consumption) (2/2)
In mining industry, the fuel consumption
common to use Fleet Management Feature in
SAP. And there is some option to allocate the
cost into : Cost Center, WBS, or Standing Order
Standing Order is a one of Order Type which
use for special treatment like fuel
consumption, this order awill never close until
Fuel Truck treat as unit has been disposed or move to other plant.
Gas Station
There are two option to input data fuel :
(Storage Location)
• Manual Transaction (IFCU)
Detail Transaction • Mass Upload by excel template (daily
Fuel upload)
Equipment : HDKMXXX Consumptio
n
Date & Time : Settlemen
t Process
01.01.2018, 08:00 Fuel
Consumptio
Standing Finial Cost
Order Receiver
Hourmeter : 1235 HR n

Lite : 36 L Fuel
Consumptio
Material : SOLAR-R n

Page 52
Install & Uninstall Equipment
Install and Uninstall Equipment work order is
to accommodate the installing and uninstalling
tire and major component on Superior
Equipment.

Superior Equipment is a superior piece of

equipment is a complex system that is made
up of several individual pieces of sub
equipment, ex : Excavator, Dump Truck.

Sub Equipment is a set of component which

have no use except being attached to superior
equipment, ex : Tire, Engine, Transmission.

Page 53
 Thank You for Your Attentions
End of Presentation

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