SAP PM (PLANT MAINTENANCE)

 By using plant maintenance we avoid the Breakdown of equipment.

 We can increase life time of equipment.
 We can increase Cost-cutting.
 We can increase productivity and utilization of man power.
 We can increase revenue of Organization.

 General in domain we have two terminologies

i. MTTR (Mean Time to Repair).
ii. MTBR (Mean Time b/w Repair).

Master Data
 Work Center
 Functional Location
Technical Objects
 Equipment
 Bill of Material
 Task list Quantitative
 Characteristics
 Class Qualitative
 Measuring Pointers, Measuring Counters
 Permits
 Warranties
 Catalog

SAP STANDARD BUSINESS PROCESS

 General Maintenance Process.
 Breakdown or Malfunction Maintenance Process.
 Preventive Maintenance Process.
 Calibration Maintenance Process.
 Refurbishment Maintenance Process.

SAP Implementation Phases

 Project Preparation
 Business Blueprint
 Realization Phase
 Final preparation
 Go live
Landscape
 Development Server/System
 Quality Server/system
 Production Server/system
 Sand Box

SAP ORGANIZATION STRUCTURE

CLIENT

COMPANY CODE

PLANT

Storage Location

Client
 Client is nothing but an Organization, Services and Firm.
 Client can run ‘n’ number of business process.
 Client is defined by BASIS Consultant.
 Can define with 3 Alpha Numeric characters.

Company Code
 It is an individual account entry.
 Whenever balance sheet is require there company code is require.
 It is defined by FICO Consultant.
 Can define with 4 Alpha Numeric characters.

Plant
 Plant is nothing but where production/manufacture taking place.
 It is defined by MM Consultant.
 Can define with 4 Alpha Numeric characters.
Storage Location
 It is used to store raw material, Semi finished goods and Finished goods.
 Can be defined with 4 Alpha Numeric characters.

Plant
Maintenance Plant (4AN)
 It is physical plant.
 Where manufacture or production taking place.
 In maintenance plant we have WORK CENTER.
 Work center is nothing but Person, Group of persons and Machine, group of Machines.
 Can define with 8 Alpha Numeric characters.
 In Maintenance Plant we have PLANT SECTION.
 Further low level identification of location.
 Can define with 3 Alpha Numeric Characters.
 It is defined by MM Consultant.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE IMG> SAP
CUSTOMIZING IMPLEMENTATION GUIDE>ENTERPRISE STRUCTURE> DEFINITION>LOGISTICS –
GENERAL>DEFINE, COPY, DELETE, CHECK PLANT.
T CODE: OX10

Maintenance Planning Plant (4AN)

 It is assumed or virtual or orbital plant.
 Where the maintenance activities/tasks are planned for Maintenance Plant.
 In Maintenance Planning Plant we have PLANNER GROUP.
 Can define with 3 Alpha Numeric Characters.
 It is defined by PM Consultant.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE IMG> SAP
CUSTOMIZING IMPLEMENTATION GUIDE>ENTERPRISE STRUCTURE> DEFINITION>PLANT
MAINTENANCE>MAINTAIN MAINTENANCE PLANNING PLANT.

ASSIGN MAINTENANCE PLANNING PLANT TO MAINTENANCE PLANT:

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE IMG> SAP

CUSTOMIZING IMPLEMENTATION GUIDE>ENTERPRISE STRUCTURE>ASSIGNMENT>PLANT
MAINTENANCE>ASSIGN MAINTENANCE PLANNING PLANT TO MAINTENANCE PLANT
 Assigning MAINTENANCE PLANNING PLANT to MAINTENANCE PLANT

MPP MPP MPP MPP

Decentralized Centralized Not Possible

MP MP MP MP

MTTR (MEAN TIME TO REPAIR)

 Keeping the contact details of technician or SME with equipment, like address, Phone number,
email id, etc.
 Keeping the user manual with equipment.
 Keeping the vendor details with equipment.
 Keeping the Design documents, Assembling, Dissembling manual with equipment.
 Keeping troubleshoot process with equipment.

MTBR (MEAN TIME B/W REPAIR)

 Here we extend maximum breakdown to breakdown by using premeasured
i. Preventive Maintenance.
ii. Shutdown Maintenance.
iii. General Maintenance.
T- CODES:
o MCJB – MTTR/MTBR EQUIPMENT
o MCJC – MTTR/MTBR FUNCTIONAL LOCATION

WORK CENTER
 Work center is nothing but Person, Group of persons and Machine, group of Machines.
 Work center contain default values that are copied or referenced in operations at the
time of task list creation. They also contain costing, scheduling and capacity data
required for lead time scheduling and capacity planning.
 Can define with 8 Alpha Numeric characters.

CREATION OF WORK CENTER

NAVIGATION: LOGISTICS>PLANT MAINTENANCE>MANAGEMENT OF TECHNICAL OBJECTS>

ENVIRONMENT>WORK CENTERS>WORK CENTER.
 T CODES:
o IR01 – CREATE
o IR02 – CHANGE
o IR03 – DISPLAY
o CR05 – LIST DISPLAY
o CR06 – WORK CENTER ASSIGNMENT TO COST CENTER
 PM Work center category : 0005

FUNCTIONAL LOCATION
 Functional location is nothing but where the equipments are placed/ installed in hierarchal
manner.
 Functional location can be structured based on Functionality, Process orientation and spatial
criteria.
 To define Functional Location we require STRUCTURE INDICATOR.
 S.I. defines with 5 Alpha Numeric Characters.
 S.I. will define the structure of the plant.
 S.I. is the combination of EDIT MASK and HIERARCHICAL LEVEL.
o Edit mask can have up to 40 Characters, including Separators.
[X – ALPHANUMERIC, N – NUMERIC, A – ALPHABETS]
o Hierarchical level will have NO LIMIT.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL OBJECTS>
FUNCTIONAL LOCATIONS>CREATE STRUCTURE INDICATOR FOR
REFERENCE LOCATIONS/FUNCTIONAL LOCATIONAS.
T CODE: OIPK
 Functional Locations can be classified in to FUNCTIONAL LOCATION CATEGORY.
 Functional Location CATEGORY is defined with 1 Alpha Numeric Character.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL OBJECTS>
FUNCTIONAL LOCATIONS>DEFINE CATEGORY OF FUNCTIONAL
LOCATION.
  Functional location VIEW PROFILE is defined with respect to functional location
category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>GENERAL DATA>SET
VIEW PROFILE FOR TECHNICAL OBJECTS
 We assign Functional Location View profile to Functional Location Category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL OBJECTS>
FUNCTIONAL LOCATIONS>DEFINE CATEGORY OF FUNCTIONAL
LOCATION.

CREATION OF FUNCTIONAL LOCATION

NAVIGATION: LOGISTICS>PLANT MAINTENANCE>MANAGEMENT OF TECHNICAL

OBJECTS>FUNCTIONAL LOCATION
T CODES:
o IL01 – CREATE
o IL02 – CHANGE
o IL03 – DISPLAY
o IH01- LIST STRUCTURAL DISPLAY

EQUIPMENT
 Equipment is a physical object which is installed/placed at Functional location.
 It requires maintenance activity.
 It is identified by its Unique Identification Number.
 Equipments can be classified into EQUIPMENT CATEGORY/Broader classification of Equipment is
known as EQUIPMENT CATEGORY.
 Equipment CATEGORY is defined with 1 Alpha Numeric Character.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>EQUIPMENT>EQUIPMENT CATEGORIES> MAINTAIN
EQUIPMENT CATEGORY
  Equipment VIEW PROFILE is defined with respect to Equipment Category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>GENERAL DATA>SET
VIEW PROFILE FOR TECHNICAL OBJECTS
 We assign Equipment View profile to Equipment Category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>EQUIPMENT>EQUIPMENT CATEGORIES> MAINTAIN
EQUIPMENT CATEGORY
 We define NUMBER RANGE with respect to Equipment Category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>EQUIPMENT>EQUIPMENT CATEGORIES> DEFINE NUMBER
RANGES
 We assign Number Range to Equipment Category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>EQUIPMENT>EQUIPMENT CATEGORIES> DEFINE NUMBER
RANGES
 We define Equipment installation allowed/not allowed at Functional Location with
respect to Equipment Category.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>
SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>EQUIPMENT>EQUIPMENT USAGE PERIOD>DEFINE
INSTALLATION AT FUNCTIONAL LOCATION
 By using Equipment Number, we can Record or Update Usage History of Equipment.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE IMG>
SAP CUSTOMIZING IMPLEMENTATION GUIDE>PLANT MAINTENANCE and CUSTIMER
SERVICE>MASTER DATA IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>EQUIPMENT>EQUIPMENT USAGE PERIOD>USAGE HISTORY UPDATE
CREATION OF EQUIPMENT:

NAVIGATION: LOGISTICS>PLANT MAINTENANCE>MANAGEMENT OF TECHNICAL

OBJECTS>EQUIPMENT
T CODES:
o IE01 – CREATE
o IE02 – CHANGE
o IE03 – DISPLAY
o IH03 – STRUCTURAL DISPLAY
o IH08 – LIST DISPLAY

(DEFINE) FIELDS IN VIEW PROFILE

TABS FIELDS
GENERAL OBJECT TYPE

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE

PROJECT>SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>GENERAL DATA>DEFINE TYPES OF TECHNICAL OBJECTS

AUTHORIZATION GROUP

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE

PROJECT>SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>GENERAL DATA>DEFFINE AUTHORIZATION GROUPS

LOCATION LOCATION

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE

PROJECT>SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>ENTERPRISE STRUCTURE>DEFINITION> LOGISTICS –
GENERAL>DEFINE LOCATION

PLANT SECTION

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE

PROJECT>SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>GENERAL DATA>DEFINE PLANT SECTIONS
 ABC INDICATOR

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE

PROJECT>SAP REFERENCE IMG> SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>GENERAL DATA>DEFINE ABC INDICATORS

ORGANIZATION PLANNER GROUP

NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE

PROJECT>SAP REFERENCE IMG>SAP CUSTOMIZING IMPLEMENTATION
GUIDE>PLANT MAINTENANCE and CUSTIMER SERVICE>MASTER DATA
IN PLANT MAINTENANCE and CUSTIMER SERVICE>TECHNICAL
OBJECTS>GENERAL DATA>DEFINE PLANNER GROUPS

[STRUCTURE] -

BILL OF MATERIAL
 Frequently repairable items keeping with TECHNICAL OBJECTS is known as Bill of Material.
 Formally structured list of components making up a technical object is known as Bill of Material.
 Bill of Material Usage for PLANT MAINTENANCE: 4
 Bill of Material are of 3 types:
I. Functional Location Bill of Material.
II. Equipment Bill of Material.
III. Material Bill of Material.

FUNCTIONAL LOCATION BILL OF MATERIAL

 It is specific to particular functional location only.
 We cannot use it for other functional location.
 It is not a reusable component.
CREATION OF FUNCTIONAL LOCATION BILLOF MATERIAL
T CODES:
o IB11 – CREATE
o IB12 – CHANGE
o IB13 – DISPLAY

EQUIPMENT BILL OF MATERIAL

 It is specific to particular equipment only.
 It is not a reusable component.
 CREATION OF EQUIPMENT BILL OF MATERIAL
T CODES:
o IB01 – CREATE
o IB02 – CHANGE
o IB03 – DISPLAY

MATERIAL BILL OF MATERIAL

 It is generic to all Technical Objects.
 It can be used for both Functional Location and Equipment.
 It is reusable component.
CREATION OF MATERIAL BILL OF MATERIAL
T CODES:
o CS01 – CREATE
o CS02 – CHANGE
o CS03 – DISPLAY
 We assign Material Bill of Material for both Functional Location and Equipment in
STRUCTURE>>CONST TYPE.

TASK LIST
 Keeping list of operations as a unit to work on Technical Objects is known as Task List.
 By using Task List we can reduce the time taking.
 These Task Lists are used in regular maintenances like General Maintenance, Preventive
Maintenance and Condition Based Maintenance.
 Generally Task Lists are used in Preventive Maintenance and Periodic Maintenance.
 By using Task List we can avoid confusion.
 Task Lists are of 3 types:
I. Functional Location Task List. (T)
II. Equipment Task List. (E)
III. General Task List. (A)

FUNCTIONAL LOCATION TASK LIST

 Functional location Task list type is ‘T’.
 Functional location Task list is specific to particular Functional location only.
 It is not reusable. We cannot use to other Functional location.
 It allows only Internal Number Ranges. It will not allow External Number Ranges.
CREATION OF FUNCTIONAL LOCATION TASK LIST
T CODES:
o IA11 – CREATE
o IA12 – CHANGE
o IA13 – DISPLAY
EQUIPMENT TASK LIST
 Equipment Task List type is ‘E’.
 Equipment Task List is specific to particular Equipment only.
 It is not reusable. We cannot use to other Equipment.
 It allows only Internal Number Ranges. It will not allow External Number Ranges.

CREATION OF EQUIPMENT TASK LIST

T CODES:
o IA01 – CREATE
o IA02 – CHANGE
o IA03 – DISPLAY

GENERAL TASK LIST

 General Task List type is ‘A’.
 It is generic to all Technical Objects.
 It can be used for both Equipment and Functional Location.
 It allows both Internal and External Number Ranges.
 It is reusable component for all Technical Objects.
CREATION OF GENERAL TASK LIST
T CODES:
o IA05 – CREATE
o IA06 – CHANGE
o IA07 – DISPLAY
 IA08 – CHANGE OVERALL TASKLIST
 IA09 – DISPLAY OVERALL TASKLIST
 IA10 – DISPLAY MULTI LEVEL TASKLIST
 In Task List we define Planner Group.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE
IMG> SAP CUSTOMIZING IMPLEMENTATION GUIDE>PLANT MAINTENANCE and
CUSTIMER SERVICE>MAINTENANCE PLANS, WORK CENTERS, TASL LISTS AND PRTS>
TASL LISTS> GENERAL DATA> CONFIGURE PLANNER GROUP.

CHARACTERISTICS
 It holds additional information to the Technical Objects.
 It may be Qualitative and Quantitative.
 Qualitative Characteristics have no units of measures and Quantitative Characteristics have
Units of measures.
CREATION OF CHRACTERISTICS:
T CODE:
o CT04 – CREATE
CLASS
 Group of Characteristics are known as Class.
 Class Types of Functional Location: 003
Equipment: 002
Material: 001
 Classes are used in Technical Objects, Order, MIC (Master Inspection Characteristics), Measuring
Pointers and Counters.
CREATION OF CLASS:
T CODE:
o CL02 – CREATION

MEASURING POINTERS, COUNTERS AND DOCUMENTS

MEASURING COUNTER
 It is Performance based
 Recording the continuous readings is known as Measuring Counter.
E.g.: Water flow, Fleets record, etc.
 Measuring Counter has Over Flow.

MEASURING POINTER
 It is Condition based
 Recording the discrete reading of Technical Objects is known as Measuring Pointer.
E.g.: Temperature, Pressure.
 Measuring Pointer has Upper Limit, Lower Limit and Target Value.

MEASURING DOCUMENT
 Measuring Document is nothing but writing/recording the readings of measuring pointer and
measuring counter.
CREATION OF MEASURING COUNTER AND MEASURING POINTER
T CODES:
o IK01 – CREATE
o IK02 – CHANGE
o IK03 – DISPLAY

CREATION OF MEASURING DOCUMENT

T CODES:
o IK11 – CREATE
o IK12 – CHANGE
o IK13 – DISPLAY
o IK51 – MEASURED READING
o IK52 – DISPLAY MEASURED READING
PERMITS WORK CLEARANCE MANAGEMENT (WCM)
 Permits are nothing but providing permission to maintenance team to work on technical
objects.
 Permits are like, Work permit, safety permit, cost permit, hazardous permit, line permit.

CREATION OF PERMITS

T CODES:
o IPMD – CREATE
o IPM3 – DISPLAY
 Permits can be assigned in two ways.
i. Directly in Maintenance Order.
ii. In technical objects (Functional Location, Equipment).

NOTIFICATION and PM ORDER

SAP STANDARD BUSINESS PROCESS ORDER TYPES
 General Maintenance Process PM01
 Breakdown/Malfunction Maintenance Process PM02
 Preventive Maintenance Process PM03
 Refurbishment Maintenance Process PM04
 Calibration Maintenance Process PM06
 Investment order PM05

 To run business process we require two components or tools.

i. Notification
ii. PM Order

NOTIFICATION/WORK REQUEST
 Notification is nothing but a tool used to raise work request.
 Notification is used to record the historical information by using CATALOGUE.
(Catalogue consists of Object Parts, over view of Damage, Causes, tasks, Activities we
define these with T CODE: QS41.)
 Any employee in organization can raise a work request for General Maintenance, For
Breakdown/Malfunction Maintenance equipment in-charge/section in-charge /operator can
rise.

SAP STANDARD NOTIFICATION TYPES

 M1 – GENERAL NOTIFICATION
 M2 – B.K.D/MALFUNCTION
 M3 – ACTIVITY and REACTIVITY
TO RAISE NOTIFICATION THE FOLLOWING ARE REQUIRE

o Technical Objects
o Notification Types
o Description of Notification
o Reported by

STATUS OF NOTIFICATION
 OSNO – OUTSTANDING NOTIFICATION
 NOPR – NOTIFICATION PUT IN PROCESS
 NOCO – NOTIFICATION COMPLETED/CLOSED
 NOPR ORAS – NOTIFICATION PUT IN PROCESS ORDER ASSIGNED

CREATION OF NOTIFICATION:

T CODES:
o IW21 – CREATE
o IW22 – CHANGE
o IW23 – DISPLAY
o IW28 – LIST CHANGE DISPLAY (IW22)
o IW29 – LIST DISPLAY (IW23)
o IW30 – MULTI LEVEL DISPLAY OF NOTIFICATION

PM ORDER/WORK ORDER/MAINTENANCE ORDER

 PM Order is a tool where we can plan for Maintenance Activities i.e., MAN POWER,
COMPONENTS, COSTING.
 MAN POWER is of 3 types Control keys
i. Internal Man Power PM01
ii. External Manpower/Labor PM02
iii. External Services PM03
 COMPONENTS can identify by using Item Category (2 types) Item Code
i. Stock Material L
ii. Non Stock Material N
 COSTING are of 3 types
i. Estimated Cost
o Before saving or releasing order we provide estimated cost for
Man Power, Components.
o It is manual entry before saving order.
ii. Planned Cost
o Order will provide planned cost automatically for Man Power,
Components.
iii. Actual Cost
o It is also automatically system generated cost.
 o Man Power – PM01 – after Time Conformation

PM02 – after Goods Receipt

PM03 – after accepting Service Entry Sheet

o Components – L – after Goods Issue

N – after Goods Receipt

STATUS OF PM ORDER
 CRTD – CREATED (IW31)
 REL – RELEASED (IW32)
 GMPS – GOODS MOVEMENT POSTED (MIGO)
 CNF/PCNF – CONFORMED OR PARTIALLY CONFORMED (IW41)[IW42 – OVERALL CONFIRM]
 TECHO – TECHNICALLY CONFORMED (IW32)
 SETL – SETTLEMENT (KO88)
 CLSD – BUSINESS CLOSED (IW32)

CREATION OF PM ORDER:

T CODES:
o IW31 – CREATE
o IW32 – CHANGE
o IW33 – DISPLAY
o IW38 – LIST CHANGE DISPLAY
o IW39 – LIST DISPLAY
o IW40 – MULTILEVEL DISPLAY OF MAINTENANCE ORDER
o IW37 – LIST CHANGE OPERATION DISPLAY
o IW49 – DISPLAY OPERATIONS
o
o ME51N – CREATE PURCHASE REQUISITION
o ME52N – CHANGE PURCHASE REQUISITION
o ME53N – DISPLAY PURCHASE REQUISITION
o ME54N – RELEASE PURCHASE REQUESTION
o
o MB1A – GOODS ISSUE

STEPS INVOLVED WHILE CREATING [PM ORDER IN CRTD] (IW31)

 MAN POWER – PM01
PM02
PM03
 COMPONENTS – L
N
 COSTING – ESTIMATED COST (MANNUAL ENTRY)
PM ORDER IN RELEASING [REL] (IW32)
 MAN POWER – PM01 – CAN DO TIME CONFORMATION
PM02 – PR (PURCHASE REQUISITION)
[PR (PM) – PO (MM) – VENDOR (FI) – GOODS RECEIPT – ACTUAL COST
REFLECTS]
PM03 – PR (PURCHASE REQUISITION)
[PR (PM) – PO (MM) – VENDOR (FI) – SERVICES PROVIDER – (AFTER
USING/WORK COMPLETE) SES (SERVICE ENTRY SHEET) ACCEPT –ACTUAL
COST FOR SERVICES REFLECTED]
 COMPONENTS – L – RESERVATION
o Based on Reservation we will receive the material or goods
from the store. (GOODS ISSUE)
o Based on Reservation store/MM people will issue goods then
actual cost will reflect.
N - PR (PURCHASE REQUISITION)
MATERIAL [PR (PM) – PO (MM) – VENDOR (FI) – GOODS RECEIPT]
o For non stock material after releasing the order PR will
generate.
o With respect to PR, PO will be generated by MM consultant.
o With respect to PO, vendor list will be taken care by FI and
vendor brings the material /services.
o After goods receipt actual cost will be reflected.
 COST – PLANNED COST (AUTOMATIC)

STEPS INVOLVED AFTER RELEASING ORDER [MIGO & CNF/PCNF]

 MAN POWER – PM01, PM02, PM03
 COMPONENTS – L, N
 COST – EXTERNAL, PLANNED, ACTUAL
 After releasing order we can do time conformation for internal man power.
 After releasing order for external services order will generate purchase requisition (PR).
 With respect to PR, MM people will generate purchase order (PO).
 With respect to PO, FI will bring goods from vendor.
 After releasing order planned cost will be reflected to all cost receiving objects (PM01, PM02,
PM03, L, and N).
 Print documents can be taken from order.
 After doing conformation for internal man power (PM01) actual cost will be reflected.
 After goods issue for stock material (L) actual cost will be reflected.
 After goods receipt for non stock material (N, PM02) actual cost will be reflected.
 After accepting SES (service entry sheet) actual cost will be reflected for external services
(PM03).
 After releasing we cannot bring back to CRTD.
STEPS INVOLVED AFTER DOING TECHO (TECHNICAL CONFORMATION) [IW32]
 If the manager satisfied with the work done by man power he conform the time conformation.
 Now technician or operator does technical conformation. I.e. now equipment is in running
condition.
 After doing technical conformation we cannot take print document.
 All open reservations will close.
 We can do settlement, posting can be allowed.
 Before doing TECHO we need to fill catalog.

SETTLEMENT
 Settlement is nothing but settling the PM order, Cost to the cost receiving objects (PM01, PM02,
PM03, L and N).
 Here actual cost becomes ZERO.
 After doing settlement we can complete the BUSINESS COMPLETION.
 After doing settlement we cannot post.

 CRTD – IW31 – PM01, PM02, PM03

L, N
ESTIMATED, PLANNED, ACTUAL (COST)
 REL – IW32 – PR (SERVICE[PM03], MATERIAL [N])
PLANNED COST
 GMPS – MIGO – GOODS ISSUE

GOODS RECEIPT

 CNF/PCNF – IW41 – PM01 – ACTUAL COST

 IW32 – TECHO – EQUIPMENT IS READY TO PRODUCTION/DISPATCH
 KO88 – SETTLEMENT – ACTUAL COST BECOMES ZERO
 CLOSD – IW32 – ORDER WILL CLOSE.

PREVENTIVE /PERIODIC MAINTENANCE (PM03)

 By using Preventive Maintenance Plan we avoid breakdown of equipment.
 We can increase uptime/life time of technical object.
 We can increase revenue of organization.
 These are can be obtained by using some pre-measures.
 We can increase the MTBF by using some pre-measures.
 These pre-measures are used in Maintenance Plan.
 To run Preventive Maintenance we require Maintenance Plan.
MAINTENANCE PLAN, MAINTENANCE ITEM AND MAINTENANCE
STRATEGY
 Maintenance plan is nothing but a tool used to plan for maintenance activities. Maintenance
plan is combination of Maintenance Item and Scheduling Parameters.
 Maintenance item consists of Technical Objects, Planning Data and Task List.
 In Maintenance Strategy we have packages of operations; we manage these packages with
hierarchy.
CREATION OF MAINTENANCE ITEM
T CODES:
o IP04 – CREATE
o IP05 – CHANGE
o IP06 – DISPLAY
o IP17 – LIST CHANGE
o IP18 – LIST DISPLAY

CREATION OF MAINTENANCE PLAN AND SCHEDULING MAINTENANCE PLAN

T CODES:
o IP01 – CREATE
o IP02 – CHANGE
o IP03 – DISPLAY
o IP16 – LIST CHANGE DISPLAY
o
o IP10 – SINGLE MAINTENANCE PLAN SCHEDULING
o IP24 – MAINTENANCE SHEDULING OVERVIEW LIST
o IP30 – DEAD LINE MONITORING (MULTIPLE PLAN SCHEDULING)

CREATION OF MAINTENANCE STRATEGY

T CODES:
o IP11 – CREATE, CHANGE
o IP12 – DISPLAY
 Preventive maintenance plan are of 3 types
I. Single cycle maintenance plan
a. Time based
b. Activity/Performance based
II. Strategic maintenance plan
a. Time based
b. Activity/Performance based
III. Multiple counter based maintenance plan
SINGLE CYCLE MAINTENANCE PLAN
 Here we require Cycle unit (duration of cycle), Scheduling period (how many days cycle run),
Technical objects, Maintenance activities or operations.
 In single cycle maintenance plan cycle unit, scheduling period and operations are fixed.
 Here scheduling indicators are Time, Time-key date and Factory calendar.

– TIME BASED
 In time based single cycle maintenance plan cycle unit is time based.

STEPS INVOLVED IN CREATING

 Create Task List (IA01/IA05/IA11)
 Create Maintenance Plan (IP01/IP41)
 Schedule Maintenance Plan (IP10)
 Release Maintenance Order (IW32)
 Goods Issue/Goods Receipt (MIGO)
 Time Conformation (IW41)
 Technical Conformation (IW32)
 Order Settlement (KO88)
 Business Completion (IW32)

– ACTIVITY BASED
 In activity based single cycle maintenance plan cycle unit is reading based.

STEPS INVOLVED IN CREATING

 Create Counter (IK01)
 Initialize the counter with Document (IK11)
 Create Task List (IA01/IA05/IA11)
 Create Maintenance Plan (IP01/IP41)
 Schedule Maintenance Plan (IP10)
 Release Maintenance Order (IW32)
 Goods Issue/Goods Receipt (MIGO)
 Time Conformation (IW41)
 Technical Conformation (IW32)
 Order Settlement (KO88)
 Business Completion (IW32)

STRATAGIC MAINTENANCE PLAN

 In strategic maintenance plan we have packages.
 A package consists of operations to do on technical objects.
 These packages are organized by using hierarchy.
 Strategic maintenance plan is a single dimension unit. (Here we can use one parameter only. E.g.
km, day, hour and month etc.)
 - TIME BASED
 In time based single cycle maintenance plan cycle unit is time based.

STEPS INVOLVED IN CREATING

 Create Strategy (IP11)
 Create Task list with strategy (IA01/IA05/IA11)
 Create Strategic Maintenance Plan (IP01/IP42)
 Schedule Strategic Maintenance Plan (IP10)
 Release Maintenance Order (IW32)
 Goods Issue/Goods Receipt (MIGO)
 Time Conformation (IW41)
 Technical Conformation (IW32)
 Order Settlement (KO88)
 Business Completion (IW32)

– ACTIVITY BASED
 In activity based single cycle maintenance plan cycle unit is reading based.

STEPS INVOLVED IN CREATING

 Create Strategy (IP11)
 Create Measuring Counter (IK01)
 Initialize Measuring Counter with Document (IK11)
 Create Task list with strategy (IA01/IA05/IA11)
 Create Strategic Maintenance Plan (IP01/IP42)
 Schedule Strategic Maintenance Plan (IP10)
 Release Maintenance Order (IW32)
 Goods Issue/Goods Receipt (MIGO)
 Time Conformation (IW41)
 Technical Conformation (IW32)
 Order Settlement (KO88)
 Business Completion (IW32)

Multiple counter based maintenance plan

 It is two dimensional.
 Here we use either time based or activity based.
CREATION OF MULTIPLE COUNTER BASED MAINTENANCE PLAN
T CODE:
o IP11Z – CREATE
CALIBRATION MAINTENANCE ORDER (PM06)
 Testing the accuracy of test equipment is known as Calibration.
 Order type should be Calibration Order (PM06).
 Order type should be assigned with INSPECTION TYPE ’14’ (Plant Maintenance).
This will be done in SPRO ones only.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE
IMG>SAP CUSTOMIZING IMPLEMENTATION GUIDE>PLANT MAINTENANCE and
CUSTIMER SERVICE>MAINTENANCE AND SERVICE PROCESSING>FUNCTIONS AND
SETTINGS FOR ORDER TYPES > ASSIGN INSPECTION TYPES TO MAINTENANCE/SERVICE
ORDER TYPES.
PLANT ORDER TYPE INSPECTION TYPE
1000 PM06 14

MIC – MASTER INSPECTION CHARACTERISTICCS

 It is one type of characteristics, which may be Qualitative or quantitative.
Quantitative: e.g. 1000g weighing machine – upper limit: 1002g, target value: 1000, lower limit:
998g.
Qualitative: only character attributes. E.g.: yes/no.
 Qualitative can be done by using CATALOGUE.
(T CODE: QS51 SELECT ‘1 – Characteristic Attributes’).

CREATION OF MASTER INSPECTION CHARACTERISTICS

T CODES:
o QS21 – CREATE
o QS22/23 – CHANGE
o QS24 – DISPLAY

SAMPLING PROCEDURE
 Sampling procedure defines how much sample size we are taking for sample.

CREATION OF SAMPLING PROCEDURE

T CODES:
o QDV1 – CREATE
o QDV2 – CHANGE
o QDV3 – DISPLAY
  While creating Calibration Maintenance Order we create a calibration task list. In this we must
provide INSPECTION POINT in QM data. Inspection Point ‘300’ for Equipment and ‘310’ for
Functional location.
 Calibration Maintenance Process is TWO types. PLANNED and UN PLANNED.

STEPS INVOLVED IN CALIBRATION MAINTENANCE PROCESS – UNPLANNED

 Create Task List (IA01/IA05/IA11)
 Create Maintenance Order (IW31) [PM06]
 Assign Task List (IW32)
 Release Maintenance Order (IW32)
 After Releasing Order Inspection lot will generated
 Results record with the Inspection Lot (QA32)
 Now we will do the Usage Decision based up on Results recorded (QA32/QA11)
 Time Confirmation (IW41/IW42)
 Technical Confirmation (IW32)
 Order Settlement (KO88)
 Business Completion (IW32)

STEPS INVOLVED IN CALIBRATION MAINTENANCE PROCESS – PLANNED

 Create Task List (IA01/IA05/IA11)
 Create Maintenance Plan (IP01) [PM06]
 Schedule Maintenance Plan (IP10)
 Inspection lot will generated
 Results record with the Inspection Lot (QA32)
 Now we will do the Usage Decision based up on Results recorded (QA32/QA11)
 Time Confirmation (IW41/IW42)
 Technical Confirmation (IW32)
 Order Settlement (KO88)
 Business Completion (IW32)
 In task list after providing select operations which are to be performed and click on
[Link] (below) assign MIC & SP SAVE
REFURBISHMENT MAINTENANCE PROCESS (PM04)
 Reconditioning of equipment is known as Refurbishment.
 To create Refurbishment Order, Order type should be selected as Refurbishment Order in SPRO.
It will be done ones only.
NAVIGATION: TOOLS>CUSTOMIZING>IMG>SPRO - EXECUTE PROJECT>SAP REFERENCE
IMG>SAP CUSTOMIZING IMPLEMENTATION GUIDE>PLANT MAINTENANCE and
CUSTIMER SERVICE>MAINTENANCE AND SERVICE PROCESSING>FUNCTIONS AND
SETTINGS FOR ORDER TYPES >INDICATE ORDER TYPES FOR REFURBISHMENT PROCESS.
ORDER TYPE SHORT TEXT REFURBISHMENT ORDER
PM04 REFURBISHMENT ORDER 
 Material should be SERIALIZED.
 Materials should maintain Valuation types and Valuation categories.
C1 – NEW
C2 – REUSE C3 – DAMAGE

C1+C2+C3 = Valuation Category

CREATION OF REFURBISHMENT ORDER

T CODES:
o IW81 – CREATE
o IW32 – CHANGE
o IW33 – DISPLAY
o IW38 – LIST CHANGE DISPLAY
o IW39 – LIST DISPLAY

MATERIAL SERIALIZATION

T CODES:
o IQO1 – CREATE SERIAL NUMBER
o IQ02 – CHANGE
o IQ03 – DISPLAY
o IQ09 – LIST DISPLAY
 OTHER T CODES:

o MB11 – DISPLAY OF MATERIAL

o MMBE – STOCK OVER VIEW
o MB1C – STOCK INCREASE
o MM02/MM03 – CHANGE MATERIAL
o MB51 – MATERIAL DOCUMENT LIST
o MB53 – PLANT STOCK AVALABILITY

STEPS INVOLVED IN REFURBISHMENT MAINTENANCE PROCESS

 Create refurbishment maintenance order (IW81)
 Release maintenance order (IW32)
 Goods issue (MIGO)
 Time conformation (IW41)
 Goods return/Goods delivery (IW8W)
 Technical confirmation (IW32)
 Settlement (KO88)
 Business completion (IW32)
 IN REFURBISHMENT MAINTENANCE PROCESS SETTLEMENT DONE FOR MATERIAL ONLY.
IMPLEMENTATION PHASES
The phases involved in project implementation are,

I. Project preparation
II. Business blue print
III. Realization
IV. Final preparation
V. Go live

PROJECT PREPARATION PHASE

 In this phase we study the assess document and existing system. If client don’t have knowledge
on assess document, we will prepare assess document for them (Walking through shop floor, by
implementing our knowledge, by interacting with users and using user manual). After
preparation of assess document we will get sign off from client.

BUSINESS BLUE PRINT PHASE

 By using the assess document we prepare BBP.
 In BBP we will conduct workshop and explain step by step regarding the process. Like what is
MP&MPP, how we take Functional Location, how we identify Maintenance plan & item, creating
Measuring pointer and counter etc.
 In BBP we will provide pictorial representation.
 In BBP we implement our own knowledge by using best practices.

REALIZATION PHASE
 By using BBP we do Configurations, it is of two types i.e. Basic Configuration and Final
Configuration.
 Basic Configuration is nothing but Configuring within our module and Final Configuration is
configuring with other modules.
 Gap analysis: Whenever we are not able to meet the client requirement in configuration is
known as gap. To full fill this we will take The ABAPER help. This is known as Gap analysis.

FINAL PREPARATION
 In this phase we will provide User manual, Configuration Documents, UATs, Integration Test
Screen Prints, LSMW & BDC programs.

GO LIVE
Providing the Legacy System to SAP System and uploading all the Master Data to SAP system by using
LSMW & BDC and hand over the same to client.
LANDSCAPE

DEVELOPMENT SERVER

Golden Client – 100

Development server

Development client – 110

Golden Client
 It allows only Configuration data.
 It will not allow Master data and Transaction data.
 We cannot load Sample data for Testing.
 Here we will not do Testing.
 Whenever we do configuration in SPRO, we get a request called Transport Request.
 If we save Transport request we will get Transport Request File.
 Generally we release the Transport Request before moving it to other clients (Quality client, Pre
production and Production etc).
 To release Transport Request
T codes: SE01 to SE10.

Development Client
 It allows Master data and Transaction data.
 We can load sample master data.
 Unit test will do in Development Client.
 Unit test is nothing but testing within our module in front of key users.
 It will not allow Configuration data.
 Golden client and Development client are in same server, we copy Transport requests from
Golden client to Development client by using
T code: SCC1.

QUALITY SERVER

Integration Client/Quality Client – 200

Quality Server
Training Client – 210
Integration Client/Quality Client
 Here we can load Master data and Transaction data.
 It will not allow configuration data.
 Here we do Integration Testing.
 Involving with other modules is known as Integration Testing.
 Here we move Transport Requests from Golden client to Quality client by BASIS by using
T code: STMS.
 To move Transport Requests from Golden client to Quality client, we must release the Transport
Requests in Golden client by using
T codes: SE01 to SE10.

Training Client
 In Training client we provide training to the end users.
 We will take the UAT (User Acceptance Test).
Sign off after providing training to the client.
 In Quality client we will provide the user manual and integration testing manuals to the power
users.
 Here we move Transport requests from Golden client to Training client by using ‘STMS’.

PRE PRODUCTION SERVER

 In Pre Production server we will upload all master data and these will be tested by users.
 It user satisfies we will plan to move the same to Production server.

PRODUCTION SERVER
 Here all master data will be uploaded in to legacy system by using LSMW and BDC.