Notes on SAP Plant Maintenance Module

Dr. Eng. Samir Lotfi Ali

1 MDC| Dr. Samir Ali| Notes on SAP PM

 Contents
SAP Plant Maintenance Module ......................................................................................... 6
Plant Maintenance Processes ......................................................................................... 6
Technical Object Management ....................................................................................... 6
Maintenance processing ................................................................................................ 7
The Preventive Maintenance component ....................................................................... 7
Business Process & Master Data Impacts ....................................................................... 7
Organization Structure of SAP PM/EAM ............................................................................. 8
Client ............................................................................................................................. 9
Controlling area “for cost accounting purpose” .............................................................. 9
Company Code ............................................................................................................. 10
Maintenance Plant ....................................................................................................... 10
Maintenance Planning Plant ......................................................................................... 10
The Maintenance Planner Groups ................................................................................ 10
Plant section ................................................................................................................ 11
Work Center................................................................................................................. 11
Technical Object .............................................................................................................. 12
Structure of Technical Objects...................................................................................... 12
Catalog Profile .......................................................................................................... 12
Locations Floc “Functional Location” ............................................................................ 13
Functional Location category .................................................................................... 14
Functional Location Structure Indicator .................................................................... 14
Master Data ..................................................................................................................... 15
Equipment ....................................................................................................................... 15
Equipment Master ....................................................................................................... 15
Equipment Classification .............................................................................................. 16
Equipment Categories and Equipment Codification .................................................. 16
Equipment task list ....................................................................................................... 16
Equipment Bill Of Material BOM .................................................................................. 17

2 MDC| Dr. Samir Ali| Notes on SAP PM

 VED .......................................................................................................................... 17
Functional Locations BOM ............................................................................................ 18
Material BOM .............................................................................................................. 18
SAP Tips and Tricks Improve Efficiency with Equipment Bill of Materials ...................... 18
Spare Parts Planning .................................................................................................... 18
Spare Parts / Assemblies / Components codification .................................................... 19
Equipment Multi Level Structure List............................................................................ 20
Maintenance Plan ............................................................................................................ 21
Budget ............................................................................................................................. 22
Work Order “The maintenance Order”............................................................................. 23
SAP work order types ................................................................................................... 23
Work order list ............................................................................................................. 23
Generic functions for SAP object ...................................................................................... 24
Maintenance Strategy ...................................................................................................... 24
Maintenance Strategy Structure .................................................................................. 26
Scheduling Parameters ................................................................................................. 26
Maintenance Packages ................................................................................................. 27
Maintenance Cycle and Maintenance Package ............................................................. 27
Master Maintenance schedule ......................................................................................... 27
Safety, Operations and Environment critical equipment .................................................. 27
The ABC Indicator......................................................................................................... 27
class / characteristics Status ......................................................................................... 28
Capacity Requirements Planning in Plant Maintenance (PM-WOC-CP) ............................. 30
Use............................................................................................................................... 30
Integration ................................................................................................................... 30
Notification Types ............................................................................................................ 31
Maintenance Order Types ................................................................................................ 31
Manage Test Equipment Calibration Processes with SAP Plant Maintenance and Quality
Management ................................................................................................................... 32
Main Master Data Preparation ..................................................................................... 34

3 MDC| Dr. Samir Ali| Notes on SAP PM

 Maintain the PRT in the Equipment .......................................................................... 34
Create an MIC Master Inspection Characteristics ..................................................... 35
Create a Task List...................................................................................................... 46
Create a Maintenance Plan ...................................................................................... 49
Transactional Data ....................................................................................................... 51
Schedule Maintenance Plan ..................................................................................... 51
Display the Calibration Maintenance Order .............................................................. 54
Display the Inspection Lot ........................................................................................ 55
Results Recording ......................................................................................................... 57
Record the UD Usage Decision ................................................................................. 58
Display PM Notifications .......................................................................................... 61
Update the Confirmation Time in the Maintenance Order ........................................... 62
Flag the Maintenance Order as Technically Complete .................................................. 64
Run Reports ................................................................................................................. 65
Customizing Activities .................................................................................................. 65
Define the Order Type .............................................................................................. 65
Assign the Inspection Type to the Order Type .......................................................... 66
Inspection Point ....................................................................................................... 67
Define a Control Key ................................................................................................. 69
Follow-Up Actions .................................................................................................... 71
Define Inspection Types ........................................................................................... 73
Maintain Inspection Lot Origins and Assign Inspection Types ................................... 74
Define Default Values for Inspection Type ................................................................ 76
Define Notification Types ......................................................................................... 77
Work Permits ................................................................................................................... 78
Maintenance KPIs ............................................................................................................ 79
SAP RDS Asset Analytics KPI’s for Enterprise Asset Management ................................. 79
Standard SAP Plant Maintenance Reports ........................................................................ 81
The list of PM Standard Report Available ..................................................................... 82

4 MDC| Dr. Samir Ali| Notes on SAP PM

 Maintenance Processing .......................................................................................... 82
Maintenance Task Lists ............................................................................................ 83
Information Systems ................................................................................................ 83

5 MDC| Dr. Samir Ali| Notes on SAP PM

 SAP Plant Maintenance Module
 The SAP PM module consists of activities such as:
o Management of Technical Objects,
o Maintenance Processing, and
o Preventive Maintenance.
 It is used to comprehensively Plan, Schedule, and Execute the daily maintenance
activities with integration to other SAP modules.
 For mobile use, the system can be accessed by using SAP’s own solution, Fiori.

Plant Maintenance Processes

 Routine/Predictive Maintenance
 Breakdown Maintenance
 Preventive Maintenance (based on duration and measuring point)
 Refurbishment Spares
 Improvement / Development / Modification / Re-design Maintenance
 Shutdown Maintenance (Planned maintenance) (PM07)
 General Maintenance (to be done through maintenance request)
 Annual Maintenance Orders
 Maintenance Budgeting (Through FI/CO Module)
 Condition Monitoring (Through measuring points/counters)
 Spare Part Planning
 Report Analysis

Technical Object Management

 It consists of activities including:
o Inspection: to measure and follow the actual condition of a technical
object.
o Preventive Maintenance: to foresee the need of repairs and upkeep the
optimal condition of technical object.
o Repair: to measure and restore the technical object.
o Other maintenance-related activities (SAP Help 2017a, cited 13 Jan 2017.)

6 MDC| Dr. Samir Ali| Notes on SAP PM

 Maintenance processing
 It helps to control the actual maintenance work conducted in the maintenance
plant. The process consists of three areas:
o Maintenance notification: to report a malfunction or to describe the
technical object condition 19
o Maintenance order: to make detailed maintenance plan and to monitor
work progress and settle the maintenance costs
o Maintenance history: to save the important maintenance data for
reporting and evaluation (SAP Help 2017b, cited 13 Jan 2017.)

The Preventive Maintenance component

 The Preventive Maintenance component can be used to:
o Store Task Lists of activities to be performed
o Specify the extent of inspection work, preventive maintenance, and
scheduling of the activities
o Specify the Recurring maintenance frequency
o Specify the Cost-Based assignment of inspection activities and preventive
maintenance
o Evaluate costs of future preventive maintenance and inspection work (SAP
Help 2017c, cited 13 Jan 2017.)

Business Process & Master Data Impacts

a) Material Planning based on maintenance task lists and maintenance order.
b) Management and scheduling of maintenance plans.
c) Creation of maintenance notifications
d) Performance of maintenance orders
e) Location-wise analyses on different performance parameters like costs,
downtime's, breakdowns etc. are possible at the Planning Plant level.
f) Definition of technical objects, maintenance task lists etc.

7 MDC| Dr. Samir Ali| Notes on SAP PM

 Organization Structure of SAP PM/EAM
 Plants
 Maintenance Plant
 Locations
 Planner Group
 Functional Location category
 Functional Location Structure Indicator
 Equipment Categories and Equipment Codification
 Spare Parts / Assemblies / Components codification
 Technical Object Types
 Catalog Profile
 Notification Types
 Maintenance Order Types
 Assignment of Notification Types to Order Types

8 MDC| Dr. Samir Ali| Notes on SAP PM

 Client

 It is the highest hierarchical unit in the SAP system. All areas of an organization
that are to be integrated into SAP, should be included under one client.

Controlling area “for cost accounting purpose”

 An organization unit within a company used to represent a closed system for cost
accounting purpose.
 A controlling area may include single or multiple company codes that may use
different currencies.
 These company codes must use the same operative chart of accounts.
 All internal allocations refer exclusively to objects in the same controlling area.

9 MDC| Dr. Samir Ali| Notes on SAP PM

 Company Code
 It is the smallest organizational unit of Financial Accounting for which a complete
self-contained set of accounts can be drawn up for purposes of external reporting.
 This includes recording of all relevant transactions and generating all supporting
documents required for financial statements.

Maintenance Plant
 A Maintenance Plant is an organizational unit within Logistics, serving to subdivide
an enterprise according to procurement, maintenance, and materials planning.
 The maintenance plant is used to indicate the location where the technical objects
are installed and actual maintenance activities are performed.
 A PM structure can consist of several maintenance plants. (SAP Help 2016a, cited 3
Nov 2016.)
 A company can have several units at its location where maintenance activities can
be performed.
 These units can be warehouses, production, or service premises.
 For planning and scheduling purposes, maintenance plants are assigned to one or
more maintenance planning plants.

Maintenance Planning Plant

 Maintenance planning plant is a logical location where the maintenance activities
on technical objects are planned.
 Maintenance planning plants determine if the maintenance planning is centralized,
decentralized or partially centralized.

The Maintenance Planner Groups

 A group of employees responsible for planning, processing, execute and monitor
the maintenance activities
 The activities performed by maintenance planner groups are:
 Defining task lists
 Planning materials, based on the BoM and related orders
 Scheduling plans for the maintenance activities
 Creating maintenance notifications

10 MDC| Dr. Samir Ali| Notes on SAP PM

  Executing maintenance orders (SAP Help 2016b, cited 2 Nov 2016.)

Plant section
 Plant sections are processing units/ production areas within a maintenance plant.
 These are subdivision of maintenance plants.
 Machines or sets of machines that are represented in the system as pieces of
equipment or functional locations are installed in plant sections.
 We can indicate the place for which a maintenance task was requested with the
plant section.
 We also, can establish a contact person for Plant Maintenance using the plant
section.

Work Center
 Work Center is an organizational unit that defines where and when an operation
must be performed. The Work Center has an available capacity. The activities
performed at or by the Work Center are evaluated by charge rates,

11 MDC| Dr. Samir Ali| Notes on SAP PM

 Technical Object

Structure of Technical Objects

 Different types of structures can be used for technical object as per the structure
of the organization. Following are the options −
 Functional Structuring
 In this type of structure, you divide your technical system as per functional
locations. With the division of the product line into functional locations, an
individual unit can act as functional locations in the system.
 Object Related Structuring
 In this structuring, you divide your technical system into pieces known as
equipment. An equipment is an individual object, which can be placed in a
technical system or a part of the technical system.
 Functional and Object-based Structuring
 It is a combination of both the functional and object-related structuring using
equipment and they are divided as per functional location.
 In this structuring, your functional location tells where the technical tasks are
performed and equipment represents the object with which tasks have to be
performed.

Catalog Profile

Combination of code groups, which determine from a functional viewpoint, which code
groups can be used for a particular technical object.
The following catalogs would be used. Common catalog profile will be used for different
technical object types.

 Coding of breakdowns - D
 Object parts – B
 Problem/Event Codes – 4
 Cause Codes – 5
 Activity Codes – A

We shall be using common catalog profile for all equipment. Details of the catalogs would
be maintained as follows:

 Coding: Coding of breakdowns as Serious/Semi-serious/Normal

12 MDC| Dr. Samir Ali| Notes on SAP PM

  Object Parts: All critical Mechanical and Electrical parts would be configured for
each of the technical object types defined.
 Problem/Event Codes: All problems that normally occur or might occur would be
listed for each type of Technical Object.
 Cause Codes: All probable causes of the events/problems listed above would be
configured for each technical object type.
 Activity Codes: The normal activities (generic) carried out for attending to the
problems would be configured here.
 Example: Technical Object Type : Pump

Object Parts Problems Causes Activities

Impeller Impeller Broken Improper Cleaning Cleaned
Impeller Jammed Lubrication Failure Machined
Abnormal Sound Impeller nut Loose Tightening
Bearing Bearing Damaged Life Expiry Replaced
Casing Pressure Low Misalignment Replaced
Shaft Shaft Damaged Life Expiry Replaced

Locations Floc “Functional Location”

 Location is a place in a maintenance plant at which a technical object is physically
located.
 It allows a plant to be classified according to spatial or situation criteria.
 A functional location is an organizational unit that is used to maintain the objects
of a company as per the functional area, process-related or spatial criteria.
 A functional location represents the place at which a maintenance task is to be
performed.
o Example of functional area − Pumping station
o Example of process related criteria – Modeling
o Example of spatial criteria − Store room
 Locations are used for informative assignment only.
 We can only use Locations as a match code or as parameter criteria in reporting.
 SAP have made the FLoc function very similar to the Equipment.
 However, there are some things that a FLoc cannot do, but an Equipment can:
 Time segments
 Configuration (to include configurable task lists and BOMs)
o ISU equipment tab
o PRT equipment tab

13 MDC| Dr. Samir Ali| Notes on SAP PM

 o Fleet equipment tab
o ETM equipment tab
o Serial number equipment tab
o Internal numbering
o Internal note
o Technical ID field
o Customer/vendor screen data

Functional Location category

 Functional Location Category to be used – “M” – Technical System Standard

Functional Location Structure Indicator

 We shall be using the following Structure Indicator for Functional Location Labelling:E
 INDICATOR DESCRIPTION STRUCTURE

VAL01 Indicator for Alumina Plant NNNN--AAA-AAA-XXX-XXXX-XXXXX

VAL02 Indicator for Power Plant NNNN- AAA-XXX-XXX-XXX-XXX
VAL03 Indicator for Mining Plant NNNN- AAA-XXX-XXX-XXX-XXX

A Alpha, X- Any character, N-Numeric)

Example:
1000-RED-DIG-TR0-DIGV-DIG01
1000 – Vedanta Alumina Plant
DIG – Digester Area
TR0 – Train 0 Area
DIGV – Digestion Vessel
DIG01 – Digester 01

14 MDC| Dr. Samir Ali| Notes on SAP PM

 Master Data
 Equipment Master
 Work Center Master Data
 Functional Location Master Data
 Maintenance Task List Master Data
 Strategy Plan
o For Preventive Maintenance,
o Shut down Activities,
o Calibration
 Valuation type of Spare Parts
 Catalog
 Code Group
 Budget
 Classification Creation/change of Class and Characteristics
 Scheduling for the Equipment

Equipment

Equipment Master
 Equipment for which any maintenance activities are carried out, are maintained in
the Equipment Master.
 The cost of maintenance of equipment based on type of maintenance can be
monitored.
 If the equipment is very big, then equipment and sub-equipment can be created in
SAP.

a) Equipment / Material BOM (Bill of Material)

b) Maintenance Strategy
c) Spare Parts, Components, Assemblies
d) Equipment classes and ratings (interchangeable)
e) ABC indicator in PM equipment master data
f) Equipment Criticality
g) Startup & Acquisition Date
h) Warranty

15 MDC| Dr. Samir Ali| Notes on SAP PM

 i) Permits
j) Measuring Points and Counters
k) Service Master

Equipment Classification
 The classification system allows you to use characteristics to describe all types of
objects, and to group similar objects in classes – to classify objects, in other words,
so that you can find them more easily later.
 Class is an assembly of characteristics that can be attributed to a product (or to
several similar products). It can also be defined as a grouping of similar products
according to common characteristics
 Example – Pump class, Boiler class etc.

Equipment Categories and Equipment Codification

 Equipment Category for all the equipment will be used as ‘M’

 It has been decided that the Equipment Code will be Externally generated for easy
identification and the logic for that code will be
 XX XXX NNNN
 Main Group Sub-Group Number

Equipment task list

 Equipment Task List is the description of the procedure for maintaining a
maintenance object called Equipment.
 Maintenance task lists is the generic term used for all task lists specifically to
Equipment task list.
 A maintenance task list contains operation.
 The maintenance task list uses a strategy for planning of Equipment Maintenance
for the defined period say weekly, monthly, quarterly etc.
 Operation can be processed internally or externally.
 The activities defined for an external operation are requested using orders.
 There are two types of Equipment Task List:
o Equipment Task List: Can be attached only to one Equipment
o General Task List:
 Can be attached to several Equipment

16 MDC| Dr. Samir Ali| Notes on SAP PM

  used for the Preventive Maintenance where the similar equipment
undergo Preventive Maintenance Scheduling

a) General task list

b) Preventive Maintenance,
c) Shut down Activities
d) Equipment calibration
e) Functional location task list
f) Critical Equipment performance verification

Equipment Bill Of Material BOM

 Any equipment is made of some assemblies and the assemblies are further made of
spare parts and small components down the level.
 The equipment BOM gives ready list available to record the critical spare part list for
any equipment.
 The same list can be referred to create preventive maintenance planning.
 In the equipment BOM, create the spare part list, quantity and stock type (non-stock or
stock item).
 This master helps in identifying for which material Purchase Requisition will be made or
Reservation is created.
 All Spare Parts, Consumables used in building of machine or repair will get a
unique material code.
 This code will be unique for the whole organization and will not change at Plant
level.
 Basic data of the materials will be maintained at client level while the other data
will be maintained at purchase organization and plant level.
 The material master for spare parts will have several views like Basic Data,
Purchasing View, MRP, Accounting view etc.
 The Spare Parts, which are accepted after inspection will be subjected to Quality
Inspection.
 For such material Quality Management View will be activated and necessary
master date will be created for the automatic inspection lot creation and results
recording and usage decision for the Spare parts.

VED

 For VED analysis (V-Vital, E-Essential, D-Desirable) one field will be used in the
material master of the spares so that this analysis can be done.

17 MDC| Dr. Samir Ali| Notes on SAP PM

 Functional Locations BOM
The BOM which specifically links to a Functional Location. Since Functional Location is
unique, the Functional Location BOM is also unique.

Material BOM
 For assemblies also we need to create BOM (Material BOM).

SAP Tips and Tricks Improve Efficiency with Equipment Bill of

Materials
https//www.efficientplantmag.com/2017/06/sap-tips-tricks-improve-efficiency-
equipment-bill-materials/

 A bill of materials (BOM) is a list of items used to perform maintenance activities.

 There are different types of BOMs, as they are often called but, in maintenance
functions, we generally use equipment BOMs.
 This material list is created in a hierarchal manner and associated with one specific
piece of equipment.
 BOMs can also be created for functional locations, making it efficient to select
materials.
 The second type of BOM is associated with a material type called an IBAU.
 This is a maintenance assembly list created by using individual parts tied to a
higher-level material instead of an equipment master or functional location.
 Creating a good BOM can be a critical factor in completing work for a piece of
equipment. It will, at a glance, make it possible to identify the materials needed to
service that piece of equipment.

Spare Parts Planning

 In SAP, all the spares of equipment are formally structured as maintenance bill of
material (BOM).
 The list contains the component number along with their quantity and unit of
measure.
 The components mentioned in BOM can be stock-able or non-stock-able.
 This becomes easy reference for the Spare Part Planning for carrying out
maintenance activities.

18 MDC| Dr. Samir Ali| Notes on SAP PM

 Spare Parts / Assemblies / Components codification
 All the spare parts, assemblies, components, consumables for maintenance will be
defined as material in SAP for taking them in inventory and the material code will
be externally generated.
 Logic for the material code is

XX XX XXX XXXXX

Major Group Sub Group Sub- Sub Group Material No

 The codification is external.

 It is going to be all numeric

19 MDC| Dr. Samir Ali| Notes on SAP PM

 Equipment Multi Level Structure List
https://archive.sap.com/discussions/thread/3357254

20 MDC| Dr. Samir Ali| Notes on SAP PM

 Maintenance Plan
 A maintenance plan is structured based on a maintenance strategy.
 A maintenance plan contains one or more maintenance items, in which the
maintenance objects to be maintained and the corresponding task list has been
defined.
 The maintenance tasks to be performed on a due date are determined by the
maintenance task list assigned to the maintenance item.
 The necessary maintenance orders are automatically generated for a due
maintenance date.

21 MDC| Dr. Samir Ali| Notes on SAP PM

 Budget

 Budget for maintenance can be done at the maintenance cost center level.
 Apart from budget, we can also give the planned expenses for maintenance.
 Cost center and budget will be done in CO module.

22 MDC| Dr. Samir Ali| Notes on SAP PM

 Work Order “The maintenance Order”

 (PM order) is defined as the maintenance call object

SAP work order types

 PM01 Regular Maintenance order
 PM02 Breakdown Maintenance order
 PM03 Preventive Maintenance order
 PM05 Calibration order
 SM01 Service Order

Work order list

 Tcode IW38 gives maintenance workers access to the work order list where all
released orders are available.
 Depending on the work shifts and task priorities, appropriate work orders are
chosen to be executed.
 The maintenance supervisor should release the daily planning of tasks for
completion

23 MDC| Dr. Samir Ali| Notes on SAP PM

 Generic functions for SAP object
https://www.comcol.nl/code/inkijkexemplaar/9781592299324/configuring-sap-plant-
maintenance-engels-karl-liebstuckel.pdf

Functional Material Task Maintenance

Function Equipment Notification Order
Location Number List Plan
Object information X X X X
Status management X X X X
Number assignment X X X X X X
Warranties X X X X X
Measuring
X X X X X
points/counters
Permits X X X
Partners X X X X
Documents X X X X X X
Field selection X X X X X X X
List variants X X X X X X X
Multilevel lists X X X X

Maintenance Strategy

 https//help.sap.com/doc/saphelp_scm2007/2007/en-
US/3c/abaf72413911d1893d0000e8323c4f/content.htm?no_cache=true

A maintenance strategy defines the rules for the sequence of planned
maintenance work. It contains general scheduling information, and can therefore
be assigned to as many maintenance task lists (PM task lists) and maintenance
plans as required. A maintenance strategy contains maintenance packages in
which the following information is defined

 The cycle in which the individual work should be performed (for example, every
two months, every 3,106.86 miles, every 500 operating hours)
 Other data which affects scheduling

24 MDC| Dr. Samir Ali| Notes on SAP PM

25 MDC| Dr. Samir Ali| Notes on SAP PM
  Maintenance Plan Type  Maintenance Strategy

 Single cycle plan, time-based  No

 Single cycle plan, performance-based  No

 Strategy plan, time-based  Yes

 Strategy plan, performance-based  Yes

 Multiple counter plan  No

Maintenance Strategy Structure

 A maintenance strategy consists of

 Strategy header
 Scheduling parameters
 Scheduling indicators
 Maintenance packages

 The individual components of a maintenance strategy are explained in detail below

 Strategy Header

 Name of the strategy

 Short text

Scheduling Parameters
 The scheduling parameters (for example, call horizon, shift factor) contain the
scheduling data for the respective maintenance strategy, with which you can
influence the scheduling of maintenance plans. When you create a strategy plan,
the system copies this data to the plan where you can change it.
 Scheduling Indicators
 Within a maintenance strategy, you can use different scheduling indicators to
specify the type of scheduling you require or to define a cycle set

26 MDC| Dr. Samir Ali| Notes on SAP PM

  Time-based (for example, every 30 days)
 Time-based by key date (for example, every 30 days on the 30th day of the month)
 Time-based by factory calendar (for example, every 30 working days)
 Performance-based (for example, every 50 operating hours)

Maintenance Packages
 Maintenance activities that must be performed at a particular date or point in time
are combined into maintenance packages. These contain, for example, the cycle
duration and unit of measurement. For more information, see Maintenance
Packages.
 You can create a maintenance strategy with three packages for maintaining a
pressurized tank.

Maintenance Cycle and Maintenance Package

 https//help.sap.com/doc/saphelp_scm2007/2007/en-
US/3c/abaf12413911d1893d0000e8323c4f/content.htm?no_cache=true

Master Maintenance schedule

Schedule Manager CA-GTF

Safety, Operations and Environment critical equipment

 https//archive.sap.com/discussions/thread/3296748

The ABC Indicator

 The ABC Indicator in an Equipment signifies the importance of that equipment in
the manufacturing scenario.
 This helps in prioritizing the maintenance planner to execute the maintenance
activities in the plant.

27 MDC| Dr. Samir Ali| Notes on SAP PM

  There will be four types for maintenance and one for calibration for the ABC
Indicator:
o A: Very high Production Loss
o B: Major Production Loss
o C: Minor Production Loss
o D: No production loss (Spare assembly)
o Q: Quality Loss (for Calibration Instruments)

 I have also posted this elsewhere but feel it has more relavance here.
 Can anybody explain how they deal with safety critical equipment, I am in the oil
drilling side of things and we were using the ABC indicator on an equipment record
to establish safety critical equipment, we needed to add operations criticality we
therefore just expanded the ABC indicator to encompass safety critical and
operations criticality.
 What we now need to add is environmental impact, (high, medium or low).
 This poses the problem of too many variables, considering 2 options for safety, yes
/ no. 3 for operations, high, medium and low and three for environmental, high,
medium and low.
 We were considering using the ABC indicator for the safety and operations and use
the sort field for environmental, but before we even consider this we needed to
ask the question, is there any in-built fields in SAP maintenance equipment records
that would cover this?
 Would be very interested to hear how others in the oil and gas industry cover this
as in this industry we now need to deal with all 3 conditions.
 we use the functional location and equipment classification and define
characteristics for storing this information of SCE. Values defined in these fields
are used in the prioritation of maintenance and repair work and also used in
reporting based on business requirements.
 Tom, you could use a combination of both user status's and class / characteristics
for Status's you could use

class / characteristics Status

 Environmental Critical
 Production Critical
 Safety Critical
 Hazardous Area

28 MDC| Dr. Samir Ali| Notes on SAP PM

  and then for the characteristics of the class

 Critical Item (Yes / No)

 MAE Control - Major Accent Event (Critical / Non Critical / No)
 Critical Risk Control (Safety / Envir / Production / Quality)
 Risk Control Item For
 Initial Risk Safety
 Residual Risk Safety
 Initial Risk Environment
 Residual Risk Environment
 Initial Risk Production
 Residual Risk Production
 Initial Risk Quality
 Residual Risk Quality
 Last Review Date
 Next Review Date
 Primary Function
 Registrable Plant (Yes / No)

29 MDC| Dr. Samir Ali| Notes on SAP PM

 Capacity Requirements Planning in Plant Maintenance (PM-
WOC-CP)
https//help.sap.com/viewer/51b2921a63f2483a9b3bbcfa6402226f/6.05.16/en-
US/824db0d59d2f455bb5e6b91a79fd4b34.html

Use
Capacity requirements planning supports you in detailed work scheduling for the
individual maintenance work centers (maintenance groups).
The capacities available to the work centers must be utilized as fully as possible in view of
the changing daily requirements. Therefore, capacity requirements planning can help you
in determining which work centers and individual persons are available, and help in
assigning them to orders and order operations. You can use this component to specify
which work centers or persons can or should complete which activities by which date.

Integration
You can only use this component in connection with the following application components
 Maintenance Orders (PM-WOC-MO)
 Capacity Planning (PP-CRP)

For planning at person level, you also require the following application components
 Personnel Management (PA)
 Time Management (PT)
To optimize the use of capacity requirements planning, certain settings must be made in
the system. The system administration makes the settings in the Customizing for
Production Planning and Plant Maintenance.

For further information, see Capacity Planning (PP-CRP), and the individual function descriptions in
the unit Capacity Planning in Customer Service and Plant Maintenance.

30 MDC| Dr. Samir Ali| Notes on SAP PM

 Notification Types
Various Notification Types would be configured in the System to take care of the various
types of job requirements.

NOTIFICATION TYPE DESCRIPTION

M1 Maintenance Request (Predictive w/o production loss)
M2 Breakdown Report (Breakdown Maintenance with production loss)
M3 Activity Report (Preventive Maintenance)
M4 Improvement (Modification/Development/Re-Design) Notification
M5 Safety Notification
M6 Shutdown Notification
M7 Calibration Notification
M8 Workshop Notification

Maintenance Order Types

Seven different types of Maintenance orders will be defined for the various types of
maintenance/repair activities to be carried out.

MAINTENANCE ORDER TYPE DESCRIPTION

PM01 Maintenance order w/o production loss
PM02 Breakdown order with production loss
PM03 Preventive maintenance order
PM04 Re-furbishment Order
PM05 Improvement (Modification/Development/Re-Design) order
PM06 Safety Order
PM07 Shutdown Order
PM08 Calibration Order
PM09 Workshop Orders
PM10 Annual Maintenance Contracts

31 MDC| Dr. Samir Ali| Notes on SAP PM

 Manage Test Equipment Calibration Processes with SAP Plant
Maintenance and Quality Management
https://sapexperts.wispubs.com/scm/articles/manage-test-equipment-calibration-
processes-with-sap-plant-maintenance-and-quality-
management?id=2c39e8cd893f477a9519f0524cc0d0b9.XDHXZ1wzY2x

Learn how to manage the calibration processes for a plant’s test equipment using the Plant
Maintenance (PM) and Quality Management (QM) functionalities with options available in the
SAP system. In particular, find out how to manage your calibration activities to complete
business transactions using master data from integrated modules and configuration done
based on a company’s business processes and strategies using standard options available
in the SAP system.

Key Concept

 In a company, the test equipment (i.e., measurement tools) should be checked

regularly. Planning and execution are performed using a maintenance plan that
automatically generates an inspection lot. In the SAP Quality Management (QM)
component, the measurement readings for the characteristics Length and
Diameter of a test probe pin are entered for this inspection lot. A test probe pin is a
physical device used to connect electronic test equipment to a device under test
(DUT). Usually these devices are used in case of electronic test requirements. If
measurement readings lie outside of the tolerances, for example, and adjustment
is necessary, the status of the gauge is changed accordingly and a malfunction
report is generated with the appropriate error code. The integration of Plant
Maintenance (PM) and QM is divided into two areas: test equipment
management (calibration inspection) and enhanced measurement reading entry.
 To ensure that specified performance criteria are always met, the test equipment
being used must be regularly checked and calibrated. You can use the functions of
test equipment management to perform the following actions:

 Manage equipment
 Plan and schedule inspections
 Execute orders and inspection lots for processing calibration inspections on equipment

 The business transactional flow for the calibration activities is managed mainly by
the Plant Maintenance (PM) and Quality Management (QM) modules, as shown
in Figure 1.

32 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 1
Main activities related to calibration services in SAP QM and PM

The business activities that are shown in the system are outlined in Table 1.

Main master data preparation Main transactional data

Test equipment: Test equipment has its own tab

on which the specific data relating to the Create maintenance plan
production resources/tools (PRTs) is to be Schedule maintenance plan
maintained. Note that you can manage the test Display and process calibration order: time confirmation
equipment itself as equipment master records and technical completion
equipment

33 MDC| Dr. Samir Ali| Notes on SAP PM

 Create a Master Inspection Characteristics
Display and process inspection lot: Record results
(MIC): Describe the properties that must be
recording, record errors, and perform usage decision (UD)
measured

Work center: The task list usage is important

here so that the relevant test equipment can be Display PM Notification
used in maintenance-specific task lists.

Maintenance plan: Generates an order and an

Verify equipment status change, change cycle
inspection lot. Contains an inspection plan for
modification, and update measurement documents
the test equipment.
Table 1
Business activities in the SAP system related to calibration services
Let’s delve deeper into these steps in the SAP system now.

Main Master Data Preparation

As shown in Table 1, main master data preparation consists of:
 maintaining production resources or tools (PRTs) in equipment,
 creating a Master Inspection Characteristic (MIC),
 creating a task list, and
 creating a maintenance plan.

Maintain the PRT in the Equipment

The PM department can maintain the PRT data in the equipment master data either by
using transaction code IE02 or by following menu path SAP Menu > Plant Maintenance >
Management of Technical Objects > Equipment > Change. Then, enter the equipment
number you need to update and press Enter. This action opens the screen in Figure 2.

34 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 2
PRT view of equipment

 In the PRT data tab in Figure 2, you need to maintain the Task list usage, Start
reference, and End reference fields.

Create an MIC Master Inspection Characteristics

 The QM department can create an MIC by using transaction code QS21 or by

following menu path SAP Menu > Logistics > Quality Management > Quality
Planning > Basic Data > Inspection Characteristic > Create. This path takes you to
the screen in Figure 3. For my example, you use an already existing characteristic
as shown in the screen in Figure 3.

35 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 3
MIC ZERO (General Data View)

 To create an MIC, enter the following information:

 The MIC code

 The plant code
 The type of characteristic (qualitative or quantitative)
 The status
 Language key
 Texts

36 MDC| Dr. Samir Ali| Notes on SAP PM

  Click the Quant. (quantitative) data button in Figure 3 and the system shows the
screen in Figure 4. Here, for your characteristic, you can define the following main
options: Decimal places, unit of measure, lower and upper limits, Target value, and
lower and upper plausibility limits. In Figure 3, the MIC is ZERO because in this
example it is the name for the characteristic to define zero point deviation during
the equipment test procedures.

Figure 4
MIC ZERO (Quantitative Data)

 Click the Control indicators option in Figure 3 and the system shows the screen
in Figure 5.

37 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 5
MIC ZERO (Control Indicators) details

 In this screen, you can specify the following details:

 Lower specif. limit: If set, you must enter a lower specification limit for the inspection
characteristic.
 Upper specif. limit: If set, you must enter an upper specification limit for the inspection
characteristic.
 Sampling procedure: If set, a sampling procedure must be assigned to the characteristic in
the task list.
 Required char. (characteristic): If set, the inspection characteristic must be inspected, which
leads to the fact that a UD can only be posted if you have confirmed the inspection results
for this inspection characteristic.
 Classed recording: If set, the inspection results for the inspection characteristic are
recorded as classed values.
 Defects recording: If set, an inspection characteristic is rejected. During results recording,
the function for recording defects for a characteristic is automatically called up and a
recording procedure can either be initialized by the user or performed in the background.

38 MDC| Dr. Samir Ali| Notes on SAP PM

  Click the continue icon in Figure 5 and the system shows the screen in Figure 6.

Figure 6
MIC ZERO (Control indicators) additional details

 In this screen, you can specify the following details:

 Fixed scope: If set, the number of inspected units must correspond to the precalculated
number of units to be inspected for results recording.
 Test-equi assignment: If this indicator is set, you can assign test equipment to the
inspection characteristic in the task list.
 Docu. if rejected: If set, additional text has to be entered in case the characteristic has been
rejected during the results recording.

39 MDC| Dr. Samir Ali| Notes on SAP PM

  RR change docs (create change documents during results recording): If set, change
documents are created for this inspection characteristic when results are recorded based
on characteristics.
 Record measured vals: If set, measured values for this quantitative characteristic have to
be inspected and confirmed.
 Print: If set, the inspection characteristic is printed on the inspection instruction.

 Click the Catalogs option in Figure 3 and the system shows the screen in Figure 7.

Figure 7
MIC ZERO (Assign defect codes to catalogs)

 In this screen, you can specify the defaulted defect codes for rejection.
 If you click the Catalog button in Figure 7, the system lists the defect codes, as
shown in Figure 8.

40 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 8
Display possible values for defects of measuring instruments

 In Figure 9, you can find the details of the General Data screen related to the
characteristic FULL. FULL is the name of the characteristic to define full-scale
deviation during the equipment test procedures.

41 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 9
MIC FULL (General Data)

 In Figure 10, you can view the details of the Quantitative Data screen related to the
characteristic FULL.

42 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 10
MIC FULL (Quantitative Data)

 In Figure 11, you can view the details of the first screen for the Control Indicators
Data related to the characteristic FULL.

43 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 11
MIC FULL (Control Indicators) first screen

 In Figure 12, you can find the details of the second screen for the Control
Indicators Data related to the characteristic FULL.

44 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 12
MIC FULL (Control Indicators) second screen

 In Figure 13, you can find the details of the assigned inspection catalogs codes
related to the characteristic FULL.

45 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 13
MIC FULL (assign a defect code for rejection)

Create a Task List

 The purpose of the task list is to define a set of operations that can be used in the
PM and QM module during the creation of the Maintenance Order.
 To create a task list, you can either use the transaction code IA05 or follow menu
path Logistics > Plant Maintenance > Preventive Maintenance > Work Scheduling >
Task Lists > General Maintenance Task Lists > Create. This action displays the
screen in Figure 14. For my example, you display a Task list that was already
created in the demo system, as shown in the Figure 14.

46 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 14
Display a task list

 In Figure 15, you need to select the appropriate task list and click the Operation
button to display the list of operations in the next screen (Figure 16).

47 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 15
Select a task list

Figure 16
Operation details for the task list

 In Figure 16, you can define or check the relevant operation details, such as control
key, duration, unit of measures, and activity type. Then, to save the data, click the
save icon .

48 MDC| Dr. Samir Ali| Notes on SAP PM

 Create a Maintenance Plan

 A maintenance plan that generates maintenance orders with inspection lots is to

be used to regularly monitor test equipment. Within the PM-QM link, this should
also provide the basis for further processing of the actual data determined in QM.
You want to carry out a calibration inspection at regular intervals for measurement
equipment, and wish to use a maintenance plan for this purpose. Create a new
single-cycle plan and incorporate the general maintenance task list for the
calibration inspection. Create an object list with two pieces of test equipment.
 To do so, either use the transaction code IP40 or follow menu path Logistics > Plant
Maintenance > Preventive Maintenance > Maintenance Planning > Maintenance
Plans > Create > Single Cycle Plan. This path takes you to Figure 17.

Figure 17
Create a maintenance plan

 No reference object is required. The order type is responsible for generating the
inspection lot (an inspection type for the order type is created in Customizing). The
order type must be configured so that the order generated is released
immediately.
 In the Maint. plan cat. (maintenance plan category) field in Figure 17, select
Maintenance Order from the options and then press Enter. The system then
displays the screen in the Figure 18.

49 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 18
Specify details for a maintenance plan (single-cycle plan)

 Specify details in the following fields in Figure 18:

 Cycle/Unit
 Planning plant
 Order Type: Enter PM06 for calibration

50 MDC| Dr. Samir Ali| Notes on SAP PM

  Main WorkCtr (work center)
 Priority
 Maint. (maintenance) Planner Group
 MaintActivity Type (maintenance activity type)
 Business Area

 In the Task List section, enter the data that you entered in Figure 15. After you
press Enter the system opens the screen shown in Figure 19 in which you can
select the Yes radio button and enter a date to specify the cycle start date. Click
the enter icon (the green check mark) to save the record.

Figure 19
Enter a start date for the maintenance plan

Transactional Data
Schedule Maintenance Plan

To schedule a maintenance plan, you can either use transaction code IP10 or follow menu
path Logistics > Plant Maintenance > Preventive Maintenance > Maintenance Planning >
Scheduling for Maintenance Plans > Schedule. In the initial screen that opens (not shown),
specify the maintenance plan created in Figure 15, press Enter, and follow menu path Edit
> Start.
The system then opens the pop-up screen in Figure 20.

51 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 20
Specify the start date for the schedule maintenance plan
In the Start of cycle field specify the start date of the cycle and click the enter icon to save
your data. The system then displays the information message shown in Figure 21.

52 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 21
Confirmation message that maintenance plan was scheduled
After you schedule the maintenance plan, note that the system has created a calibration
maintenance order and Inspection Lot documents automatically. I explain how to display
the calibration maintenance order and the Inspection Lot documents in the next section.

53 MDC| Dr. Samir Ali| Notes on SAP PM

 Display the Calibration Maintenance Order

To display the calibration maintenance order, you can either use transaction code IP10 or
follow menu path Logistics > Plant Maintenance > Preventive Maintenance > Maintenance
Planning > Scheduling for Maintenance Plans > Schedule.
In the initial screen (not shown), specify the maintenance plan created in Figure 15 and
press Enter. The system then opens the screen shown in Figure 21 in which you click the
display icon . The system then opens a screen with the details shown in Figure 22.

Figure 22
Display the inspection lot (data for the lot origin)

54 MDC| Dr. Samir Ali| Notes on SAP PM

 Display the Inspection Lot

To display the inspection lot, you can use transaction code QA03 or follow menu path SAP
Menu > Logistics > Quality Management > Quality Inspection > Inspection Lot > Processing
> Display. Alternatively, you can also click the display inspection lot icon in Figure 22.
The system then displays the UD data. Select the Equipment tab to view the details shown
in Figure 23.

55 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 23
Display the inspection lot (inspection specifications)
Select the line item and then click the choose object’s details icon to display the
inspection point data, as shown in the pop-up screen in Figure 23.

56 MDC| Dr. Samir Ali| Notes on SAP PM

 Results Recording
In my example, you determined during the calibration inspection that equipment
10003540 has both an invalid zero point deviation and an unacceptable full-scale
deviation. You can see the general view of these two characteristics in Figure 3 and Figure
9. The values for equipment 10003541 for both characteristics lie within the permitted
tolerances.
Based on this data, enter the inspection results using transaction code QE51N or by
following menu path SAP Menu: Logistics > Quality Management > Quality Inspection >
Worklist > Results Recording.
Expand the relevant operation in the dialog structure (left column) and double-click the
corresponding equipment for the inspection lot. Then, you can evaluate the
characteristics.
In my example, you have accepted the results record for the Equipment 10003540 and
operation 0020 and rejected the rest. Save your data. The system then displays the details
shown in Figure 24.

57 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 24
Enter and save record results for the inspection lot

 Note: Upon the saving of the rejection, the system automatically creates PM
notifications.

Record the UD Usage Decision

You can record the UD either by using transaction code QA11 or by following menu path
Logistics > Quality Management > Quality Inspection > Inspection Lot > Usage Decision >
Record. The screen in Figure 25 then appears.

58 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 25
Record the UD (enter the UD code)
The inspection lot last processed appears by default (or enter the inspection lot number).
Choose the relevant code in the UD code field (for example, A for usable) and save. Note
that when you save the UD, the window for changing the status of objects and the cycle
modification factor appears.
One response to the valuation of equipment 10003541 could be, for example, a reduction
of the cycle modification factor, which results in the maintenance cycle being shortened. A
malfunction report (category MQ) was generated with two items (zero point error and
end of scale error) and corresponding error codes. (I discuss the malfunction report for
category MG in the next section.) Measurement documents were still generated for all the
measurement readings.
Note that after you save the UD, the system displays the details of the status change for
objects or equipment, as shown in the Figure 26. You can also view these details by using

59 MDC| Dr. Samir Ali| Notes on SAP PM

 transaction code IE03 and verifying that the status of the equipment has been updated to
NPRT PRT, which is not ready for use.

Figure 26
Status change for objects or equipment

 After you press Enter to save your data, the system shows the confirmation
message shown in Figure 27.

Figure 27

60 MDC| Dr. Samir Ali| Notes on SAP PM

 Confirmation message that the UD was saved

Display PM Notifications

 Usually, you can display the PM notifications either by using transaction code IWS3
or by following menu path Logistics > Plant Maintenance > Maintenance
Processing > Notification > Display.
 In my example, however, use transaction code QA13 and in the initial screen (not
shown) enter the Inspection Lot document number and press Enter. The system
opens the screen shown in the Figure 28.

Figure 28

61 MDC| Dr. Samir Ali| Notes on SAP PM

 Trigger a display notification

 Click the Defects tab and select the item you want to consider to trigger the
notification display. Click the Display Notification button, as shown in Figure 28.
The system then displays the information as shown in Figure 29. Note that the
Notification Type is MQ - Error msg. from QM.

Figure 29
Display PM notification (item overview)

Update the Confirmation Time in the Maintenance Order

 To update the confirmation time in the Maintenance Order, you can either use
transaction code IW41 or follow menu path Logistics > Quality Management > Test
Equipment Management > Calibration Inspection > Order Confirmation >
Individual Entry. Enter the calibration order and operation in the selection screen
and then press Enter. The system displays the screen in Figure 30.

62 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 30
Order confirmation data for operation 0010

 Specify the following confirmation data:

 Personnel no.: The employee ID for the person who actually performed the work
 Actual Work: The number of hours spent to complete the work
 Reason: The reason for variance
 Confirm. (Confirmation) text: Any reasonable text to justify the work done

 Then, check that the rest of the defaulted entries are appropriate and save the
data. The system displays a confirmation message as shown in Figure 30.

63 MDC| Dr. Samir Ali| Notes on SAP PM

 Flag the Maintenance Order as Technically Complete
 Before making this step you should verify that all activities against the calibration
order have been competed (i.e., confirmation time for all operations).
 To update the PM Order as technically complete, you can either use transaction
code IW32 or follow menu path Logistics > Plant Maintenance > Maintenance
Processing > Order > Change. In the initial screen (not shown) enter the calibration
order and operation in the selection screen and press Enter. The system displays
the screen in Figure 31.

Figure 31
Order is technically complete

64 MDC| Dr. Samir Ali| Notes on SAP PM

  In the menu bar in Figure 31 click the Order button and follow menu path
Functions > Complete > Complete (technically) and save the data. The status of the
order is then updated to TECO – technically completed.

Run Reports
All affected and authorized departments can display the details of the QM and PM
documents related to the calibration processes (for example, Quality Notification,
Inspection Lot, and PM Orders) using the information system reports available under the
QM and PM modules.
These two menu paths can be used to retrieve transaction documents created in the QM
and PM modules:
In QM, follow Plant Maintenance > Information System > Report Selection > Information
Systems Information Systems system reports available under the QM Centers
Capacity/Maintenance.
In PM, follow Processing/Maintenance Planning/Maintenance Task Lists Quality
Management > Test Equipment Management > Information System >
Equipment/Maintenance/Calibration Inspection.

Customizing Activities
Define the Order Type

 In PM Customizing, you need to create an order type for the calibration inspection.
To create an order type, follow menu path Plant Maintenance and Customer
Service > Maintenance and Service Processing > Maintenance and Service Orders >
Functions and Settings for Order Types > Configure Order Types. This path takes
you to Figure 32. In the Cost accounting profiles section of Figure 32 enter the
details provided by the costing department. In the Reorganization section, enter
the residence time for archiving purposes in the Residence Time1 field. Select the
Release immediately indicator to release the order upon its creation in one step.

65 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 32
Define a calibration order type

Assign the Inspection Type to the Order Type

 In PM Customizing, you need to assign the order type for the calibration inspection
to the previously defined inspection type for PM. To complete this step, follow
IMG menu path Plant Maintenance and Customer Service > Maintenance and
Service Processing > Maintenance and Service Orders > Functions and Settings for

66 MDC| Dr. Samir Ali| Notes on SAP PM

 Order Types > Assign Inspection Types to Maintenance/Service Order Types. This
path displays the screen shown in Figure 33.

Figure 33
Assign the calibration order type to the inspection type

 In Figure 33, you can see that the plant 1000 and calibration order type PM06
combination has been assigned to inspection type 14 (inspection in PM).

Inspection Point

 In QM Customizing, you need to define an inspection point of category Equipment

or Functional location. The inspection point is entered in the task list header. To
complete this step, follow menu path Quality Management > Quality Planning >
Inspection Planning > General > Define Identifier for Inspection Points. This path
displays the screen shown in Figure 34. In the Fields tab populate the fields as
shown in Figure 34.

67 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 34
Display inspection point for equipment (fields)

 Now click the Valuation tab (Figure 35) to maintain the following default values:

 For valuating the Inspection Point

 In case all characteristics have been accepted
 In case at least one characteristic has been rejected

68 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 35
Display the inspection point for equipment (valuation)

Define a Control Key

 In QM Customizing, you need to create a control key that requires an inspection

characteristic for the task list. You define a new control key relevant for QM
activities and externally processed operations. Note that without the control key
set as described, the external process cannot be triggered from the production
order’s operation.
 To complete this step, you can either use IMG transaction code OPJ8 or follow
menu path Tools > Customizing > IMG > Edit Project (SPRO) Pushbutton: SAP
Reference IMG. Production > Shop Floor Control > Master Data > Routing Data >
Define control key. In my example, use the control keys QM01 and PM01. These
are standard SAP control keys and are displayed in Figures 36 and 37. Make sure
that the check boxes enclosed in a red border in Figures 36 and 37 have been set in
your system.

69 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 36
Display control key QM01

70 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 37
Display control key PM01

 The control key is used in the operation of the production order. To enable the
external activities functionalities with the QM module, check the Insp.char.
required check box and enter the value + in the External processing field. Save the
data by clicking the save icon.

Follow-Up Actions

 In QM Customizing, follow-up actions can be defined that can then be linked to the
codes for UDs. If a particular code is assigned when the UD is made, the assigned
follow-up actions (for example, updating measurement readings, status changes,
and so on) are executed automatically. To complete this step, follow menu path
Tools > Customizing > IMG > Edit Project (SPRO) Pushbutton: SAP Reference IMG.
Quality Management > Define Follow-Up Actions. Then select in the pop-up screen
(not shown) the activity’s option Follow-Up Actions. This action opens the screen
in Figure 38.

71 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 38
Define QM_PM follow-up actions

 In Figure 38 select the line item and select the folder Function modules. The
system opens the screen in Figure 39. In this screen you can define the list of
function modules that will be triggered upon the UD.
 I now describe the follow-up actions for the three function modules shown
in Figure 39:

 QFOA_QM_CHAR_TO_PM_E_POINTS: This follow-up action can be used to transfer QM

inspection results to the equipment or functional locations in PM as measurement
documents.

 QFOA_OBJECT_STATUS_SET: Follow-Up Action: Set Equipment Status/Change Cycle

Modification Factor

 QFOA_ORDER_TECHNICAL_COMPLETE: Follow-Up Action: Technically Complete PM

Order. This follow-up action can be used to transfer QM inspection results to the
equipment/functional locations in PM as measurement documents. AftrPst (after posting)
check box: If this check box is selected, the function module is called after posting.
Synchronous Update check box: If this check box is set, the dialog transaction and follow-
up action are updated synchronously.

72 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 39
Define function modules relevant to the QM_PM follow-up action

Define Inspection Types

 In this step you verify the customizing settings for the inspection type 14 –
Inspection in the Plant Maintenance. To complete this step follow menu path Tools
> Customizing > IMG > Edit Project (SPRO) Pushbutton: SAP Reference IMG. Quality
Management > Quality Inspection > Inspection Lot Creation > Maintain Inspection
Types. This path takes you to the screen in Figure 40.

73 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 40
Display inspection type 14

 For my example, I have used the standard Inspection Type 14 - Inspection in Plant
Maintenance. This inspection type is linked with the notification type MQ – Error
msg. from QM.

Maintain Inspection Lot Origins and Assign Inspection Types

 In this step you make sure that the Inspection Type 14 - Receiving Insp. from
External Processing has been assigned to the Inspection Origin 01 - Goods Receipt
and the Inspection Type 04 - Goods receipt inspection from production to the
Inspection Origin 04 - Goods Receipt from Production.
 To complete this step follow menu path Tools > Customizing > IMG > Edit Project
(SPRO) Pushbutton: SAP Reference IMG. Quality Management > Quality Inspection
> Inspection Lot Creation > Maintain Inspection Lot Origins and Assign Inspection
Types. This path takes you to the screen in Figure 41.

74 MDC| Dr. Samir Ali| Notes on SAP PM

 Figure 41
Display entries for inspection origin 14

 You have to link the lot origin 14, the Inspection in Plant Maintenance 14, and
status 4 - Released (general). Note that these settings should already have been
set as standard upon the QM module activation.
 Select the first line item in Figure 41 and then double-click the Inspection types for
the origin folder. The system displays the details shown in Figure 42.

Figure 42
Display the link between inspection type 14 and origin 14

 Note that the entry listed in the Figure 42 should have already been created by the
SAP system upon the activation of the QM module. In my example, the entry you
need to enable is 14 as origin of the Plant Maintenance and 14 as inspection type.

75 MDC| Dr. Samir Ali| Notes on SAP PM

  With these entries, the system automatically creates an inspection lot upon the
scheduling of a maintenance plan.

Define Default Values for Inspection Type

 In this step you define default values for inspection types 14.
 To do so, follow menu path Tools > Customizing > IMG > Edit Project (SPRO)
Pushbutton: SAP Reference IMG. Quality Management > Quality Inspection >
Inspection Lot Creation > Define Default Values for Inspection Type. Then, double-
click the line item containing the Inspection Type 14. This action opens the screen
in Figure 43.

Figure 43
Default values for inspection type 14

 In the inspection lot, with inspection type 14, enable the usage of Inspect by task
list, Record characteristic results, and Automatic usage decision indicator. Leave
the rest of the fields as defaulted. In an SAP system, the data is always saved using
the save icon.

76 MDC| Dr. Samir Ali| Notes on SAP PM

 Define Notification Types

 In this step you define the Notification document type that will be used during the
vendor’s Quality Notification processes. To complete this step, follow IMG menu
path Tools > Customizing > IMG > Edit Project (SPRO) Pushbutton: SAP Reference
IMG. Quality Management > Quality Notifications > Notification Creation >
Notification Type > Define Notification Types. When you double-click the
notification type MQ, the system displays the screen shown in Figure 44.

Figure 44
Display notification type MQ

 In Figure 44, verify that the following values are set:

 02 as Notification origin. It defines the screen sequence control for a Notification Type.
 1000_QM as Catalog profile. It restricts the list of values for the information contained in the
quality notification based on your business requirements.
 26 as Update group statistics. It is used to determine the fields that will be created for the
statistics in the Logistics Information System (LIS).

77 MDC| Dr. Samir Ali| Notes on SAP PM

 Work Permits
01 Create the maintenance order & assign WCM permit IW31
02 Create Work Approval (WAP) through Maintenance Order IW32
03 Create Work Clearance Application (WCA) from WAP WCTB
04 Create Additional Application e.g. Hot Work from WAP WCTB
05 Create Operation Work Clearance Document (WCD)
05.01 Create WCD directly & assign the safety document WCT6
05.02 Create WCD by using the WCD Template
05.02.01 Create Template for WCD WCT1
05.02.02 Create Operational WCD by using Template WCR4
06 Release the WAP WCTB
07 Release the WCA WCTL
08 Release the Additional Application WCTI
09 Issue the Permit attached with Additional Application WCTI
10 Issue the permit attached with WCA & approves Tagging WCTL
11 Release WCD to start Tagging WCT7
12 Perform Tagging for Technical objects WCT7
13 Protection of tagging condition for Technical Objects WCT7
14 Approving Safety Measurement in WCA WCT7
15 Take print out of permit from Tagged WCA WCTL
16 Release Work Order for Execution IW32
17 Perform Test Cycle for Tagging/Untagging WCTL

78 MDC| Dr. Samir Ali| Notes on SAP PM

 Maintenance KPIs

https//go.support.sap.com/kpicatalog/?temp-accept-
terms=20181024
Category Description
Service and Maintenance 60 KPIs
Asset Maintenance Cost 7 KPIs
Maintenance / Repair Order
Fullfillment 9 KPIs

SAP RDS Asset Analytics KPI’s for Enterprise Asset Management

https://blogs.sap.com/2015/03/11/sap-rds-asset-analytics-kpi-s-for-enterprise-asset-
management/

SAP Rapid Deployment Solutions Asset Analytics I

The SAP RDS Asset Analytics solution offers a range of predefined KPI’s, these KPI’s have been
categorized as:

 Maintainability
 Reliability
 Availability
 Supplies
 Sustainability
As part of the SAP RDS Asset Analytics solution there are 31 predefined KPIs,
which are listed below.

perspective Objectives KPI ID KPI Name

Maintainability Improve RDS_EAM_001 Total Person-Hour Capacity Available
Productivity for Maintenance
RDS_EAM_002 Capacity for Preventive Maintenance
RDS_EAM_003 Capacity for Predictive Maintenance
RDS_EAM_004 Capacity for Breakdown Maintenance
RDS_EAM_005 Percentage of Work Orders for
Preventive Maintenance

79 MDC| Dr. Samir Ali| Notes on SAP PM

 RDS_EAM_006 Percentage of Work Orders for
Predictive Maintenance
RDS_EAM_007 Percentage of Work Orders for
Breakdown Maintenance
RDS_EAM_008 Percentage of Work Orders for
Emergency Requirements
RDS_EAM_009 Percentage of Work Orders for Critical
Assets
RDS_EAM_010 Percentage of Capacity used for
Performing Maintenance Tasks
Improve RDS_EAM_011 Percentage of Work Orders Resulting
Effectiveness from Condition Monitoring
RDS_EAM_012 Backlog of Activities
RDS_EAM_013 Completion Rate
RDS_EAM_014 Schedule Adherence
Improve RDS_EAM_015 Notification Response Time
Efficiency RDS_EAM_017 Maintenance Cost as Percentage of
Replacement Value
RDS_EAM_018 Budget Utilization
RDS_EAM_019 Number of Work Orders per Clock
Hour
RDS_EAM_020 Number of Notifications per Clock
Hour
Improve RDS_EAM_016 Maintenance Rework
Accuracy
Reliability Reduce RDS_EAM_021 Mean Time Between Failure (MTBF)
Failures RDS_EAM_022 Mean Time To Repair (MTTR)
RDS_EAM_023 Mean Time Between Repair (MTBR)
Availability Improve Assets’ RDS_EAM_024 Technical Availability of Assets
Availability RDS_EAM_025 Operational Availability of Assets
Supplies Manage Stock RDS_EAM_026 Number of Stock Outages
outs of RDS_EAM_027 Orders Delayed Due to Stock Outages
Spare Parts
Manage RDS_EAM_029 Subcontracted Work as a Percentage
Subcontracts’ of Total Work
Work
Sustainability Manage RDS_EAM_030 Maintenance Request to Correct
Safety Safety Incidents
RDS_EAM_031 Maintenance Request to Correct
Incidents Due to Reported Injuries
Improve RDS_EAM_032 Maintenance Request to Correct
Environment Incidents related to Environmental
Compliance Compliance

80 MDC| Dr. Samir Ali| Notes on SAP PM

 Standard SAP Plant Maintenance Reports
https//blogs.sap.com/2015/03/16/standard-sap-plant-maintenance-reports/

Below is a list of standard SAP reports commonly used in Plant Maintenance, these
reports can be run as and when required provided the user has access to the transaction
code/s.

SAP Transaction Description

Code
CA82 Work Centre where-used list in task lists
CL6A Class list
CL6B Object list
CL6C Class Hierarchy
CM25 Capacity Leveling – tabular planning board – variable
CR05 Work Center list
CR06 Cost Center assignment
CR07 Work Center capacity
CR08 Work Center hierarchy
CS15 Material single-level where-used list for BOMs
CT10 Characteristics list
CT11 Characteristic Values list
IA08 Task List list(Change)
IA09 Task List list (Display)
IA10 Task list multi-level list (Display)
IE05 Equipment list (Change)
IE07 Equipment multi-level list (Display)
IH01 Functional Location structure display
IH03 Equipment structure display
IH04 Equipment BOM structure list
IH05 Material BOM structure list
IH06 Functional Location list (Display)
IH08 Equipment list (Display)
IH12 Functional Location BOM structure display
IL05 Functional Location list (Change)
IL07 Functional Location multi-level list (Display)
IP15 Maintenance Plan list (Change)
IP16 Maintenance Plan list (Display)
IP17 Maintenance Item list (Change)
IP18 Maintenance Item list (Display)
IP19 Graphical Scheduling Overview
IP24 Scheduling overview list

81 MDC| Dr. Samir Ali| Notes on SAP PM

 IP62 Material where-used list in task lists
IW13 Material where-used list for orders
IW28 Notification list (Change)
IW29 Notification list (Display)
IW30 Notification multi-level list (Display)
IW37 Operation list (Change)
IW37N Order and operation list (Change)
IW38 Order list (Change)
IW39 Order list (Display)
IW3K Component list (Change)
IW3L Component list (Display)
IW40 Order multi-level list (Display)
IW47 Time confirmation list (Display)
IW49 Operation list (Display)
IW49N Order and operation list (Display)
IW70 Order: Total network scheduling

The list of PM Standard Report Available

https://www.erpgreat.com/plant/standard-pm-reports-available-list.htm
Maintenance Processing

IW29 - Display Notifications

IW30 - Notification List (Multilevel)
IW67 - Display Tasks
IW69 - Display Notification Items
IW68 - Change Notification Items
IW65 - Display Activities
IW39 - Display Orders
IW40 - Display Orders (Multilevel)
IW49 - Display Operations
S_ALR_87013430 – Post-processing of PDC Error Records
S_ALR_87013431 - Confirmation Using Operation List
S_ALR_87013432 - Display Confirmations

82 MDC| Dr. Samir Ali| Notes on SAP PM

 S_ALR_87013433 - Display Document Flow
S_ALR_87013434 - Material Where-Used List
IWBK - Material Availability
Maintenance Planning
IP16 - Display Maintenance Plan
IP18 - Display Maintenance Item
IP30 - Deadline Monitoring for Maintenance Plan
IP19 - Graphical Scheduling Overview
IP24 - Maintenance Scheduling Overview
S_ALR_87013426 - Maintenance Plan Costing
IP14 - Where-Used List by Strategy
S_ALR_87013428 - Package Sequence Strategy
S_ALR_87013429 - Display Document Flow

Maintenance Task Lists

IA09 - Display Task Lists

IA10 - Display Task Lists (Multilevel)
IA16 - Cost Maintenance Task Lists
IA17 - Print Maintenance Task Lists
IP62 - Where-Used List for Material
IA21 - Evaluate Change Documents for Maintenance Task Lists

Information Systems

MCI1 - PMIS: Object Class Analysis

MCI2 - PMIS: Manufacturer Analysis
MCI3 - PMIS: Location Analysis
MCI4 - PMIS: Planner Group Analysis

83 MDC| Dr. Samir Ali| Notes on SAP PM

 MCI5 - PMIS: Single Object - Damage Analysis
MCI6 - PMIS: Object Statistics
MCI7 - PMIS: Breakdown Analysis
MCI8 - PMIS: Cost Analysis
MCIA - PMIS: Customer Notification Analysis
MCJB - MTTR/MTBR Equipment
MCJC - MTTR/MTBR Functional Location

84 MDC| Dr. Samir Ali| Notes on SAP PM