Corrective Maintenance

Business Process Overview

This Business process explains the process of Corrective Maintenance in SAP ECC.

Corrective maintenance is defined as maintenance work which involves the repair or replacement of components which have
failed or broken down. Corrective maintenance is carried out on all items where the consequences of failure or wearing out are not
significant and the cost of this maintenance is not greater than preventative maintenance.
Corrective maintenance is the most commonly used maintenance approach, but it is easy to see its limitations. When equipment
fails, it often leads to downtime in production, and sometime it causes spreading of damage to other parts. In most cases this is
costly business. Also, if the equipment needs to be replaced, the cost of replacing it alone can be substantial. Reliability of
systems maintained by this type of maintenance is not known and cannot be measured. Therefore, corrective maintenance is
carried out on all items where the consequences of failure or wearing out are not significant.

Business Sub-Process Description

The process of corrective maintenance begins with the failure and a diagnosis of the failure to determine why the failure appeared.
It is important to determine what caused the problem in order to take appropriate action, and to be aware that multiple failures of
components may have occurred simultaneously.

The next step is replacement of damaged components. In some cases, the damage may be repairable, either on site or by
removing the item in question and doing repairs off site. In other instances, full replacement with a new item may be required to
restore the system's functionality.

After the corrective maintenance is performed, a technician verifies that the fix has worked by testing the system. This may be
done in several stages to confirm that the system is operational slowly before overloading it with tasks. Verification is especially
important on systems sent in to a facility for repair, as the technicians want to be sure that when they are sent back out, the users
will be happy with the standard of the work performed

The typical steps contained within the corrective maintenance process, including breakdown maintenance, can be summarized in
the following eight activities:

1. Request and Acceptance

2. Work Order Creation
3. Work Planning
4. Cost / Budget Control
5. Cost and Safety Approval
6. Scheduling
7. Execution
8. Feedback and Completion

Sub ProcessActivities

Key Assumptions
The assumption has been made that the equipment will be recorded as assets and therefore has a zero stock value.

Process Objective
 High level of system availability of critical equipment/spare parts.

Process Flow and descriptions

1. Request and Acceptance:Creation of a notification regarding a malfunction/defect or a request for a particular

maintenance task.
2. Work Order Creation:Creating a work order based on the notification to enable the planning and scheduling of
the maintenance work.
3. Work Planning:Typical planning tasks include creating operations, reserving spare parts, requesting the
procurement of materials and services, and planning execution times.
4. Cost / Budget Control:Supporting decision making by providing visibility regarding the cost of the maintenance
work, and the impact it will have on the budget.
 5. Cost and Safety Approval:The approval of the work order cost as well as the safety measures incorporated to
ensure the safe execution of the work.
6. Scheduling:Scheduling the work order with availability checks, and capacity provisions.
7. Execution:Executing the maintenance work includes the printing of due work order papers, the withdrawal of
spare parts from the warehouse and the physical execution of the work.
8. Feedback and Completion:Completion of the work actually executed, recording of actual time to complete the
task and any findings, such as recording of the cause of the malfunction/defect. The order is settled in Controlling.

Client
Step Menu Path Configuration Task Name T-Code Dependent

SAP Customizing->Plant Maintenance and Customer service

->Maintenance Processing->Maintenance and Service
Define Notification Types SPRO Yes
Notification->Notification Creation->Notification Types-
1 >Define Notification Types

SAP Customizing->Plant Maintenance and Customer service

->Maintenance Processing->Maintenance and Service Set field selection for
SPRO Yes
Notification->Notification Creation->Notification Types->Set Notification
2 field selection for Notification

SAP Customizing->Plant Maintenance and Customer service

->Maintenance Processing->Maintenance and Service Define Number Ranges for
SPRO Yes
Notification->Notification Creation->Notification Types- Notification
3 >Define Number Ranges

SAP Customizing->Plant Maintenance and Customer service

->Maintenance Processing->Maintenance and Service
Maintain Catalog SPRO Yes
Notification->Notification Creation->Notification Content -
4 >Maintain Catalog

SAP Customizing->Plant Maintenance and Customer service

->Maintenance Processing->Maintenance and Service Order-
Configure Order Types SPRO Yes
>Functions and setting for Order Types->Configure Order
5 Types

SAP Customizing->Plant Maintenance and Customer service

->Maintenance Processing->Maintenance and Service Order-
>Functions and setting for Order Types->Configure Number Configure Number Ranges SPRO Yes
Ranges

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and Assign Order Types to
SPRO Yes
setting for Order Types->Assign Order Types to Maintenance Plant
7 Maintenance Plant

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
setting for Order Types->Define Default Value for Planning Define planning indicator SPRO Yes
Indicator for Each Order Type

8
 9
Plant Maintenance and Customer service ->Maintenance
Processing->Maintenance and Service Order->Functions and Define the settlement rules SPRO Yes
setting for Order Types->Settlement Rule: Define Time and
Creation of Distribution Rule

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
setting for Order Types-> Define Proposed Reference Time Define Reference Time for
SPRO Yes
for Technical Completion technical Completion

10

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
setting for Order Types-> Control Key >Maintain Maintain Control key SPRO Yes
Control Keys

11

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
Maintain Default control Key SPRO Yes
setting for Order Types-> Control Key >Maintain
12 Default Values for Control Keys for Order Types

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
Define activity type SPRO Yes
setting for Order Types-> Maintenance Activity
13 Type>Define Maintenance Activity Types

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and Assign Maintenance activity to
SPRO Yes
setting for Order Types-> Maintenance Activity Order Type
14 Type>Assign Maintenance Activity Types to orders

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
Assign default activity to Order
setting for Order Types-> Maintenance Activity Type> SPRO Yes
Type
Default Values for Maintenance Activity Type for Each
15 Order

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
Assign costing parameter to
setting for Order Types-> Costing Data for SPRO Yes
order type
Maintenance and Service Orders>Assign Costing
16 Parameters and Results Analysis Keys

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and Setting for operation increment,
SPRO Yes
setting for Order Types-> Define Change collective P R
17 Documents, Collective Purchase Requisition, MR

Plant Maintenance and Customer service ->Maintenance

Processing->Maintenance and Service Order->Functions and
Setting for material availability SPRO Yes
setting for Order Types-> Availability Check for
18 Material, PRTs, and Capacities>Define Inspection Control

SAP Customizing->Plant Maintenance and Customer

Define Permit Categories SPRO Yes
19 service->Basic settings-> Permits-> Define Permit
Categories
 SAP Customizing->Plant Maintenance and Customer service
->Maintenance Processing->Maintenance and Service Order- Define Control Parameters for
SPRO Yes
>Completion Confirmation>Define Control Parameters for completion Confirmation
20 completion Confirmation

Name Description Transaction Code, Roles involved Regulatory /Other

if relevant Controls

Reporting Reporting Equipment

Equipment failure/Maintenance required
failure/Maintenance
required

Create Notification. Notification is created as per the IW21 Maintenance

requirement. planner.

Input:

Notification type

Change Notification / Data is entered in notification IW22 Maintenance

Enter data. mentioning tech object, object Engineer.
part, damage, priority etc and
saved.

Input:

Notification number.

Notification put in Notification is further checked IW22 Maintenance

process. and then released by selecting planner.
the green flag and put in process.

Input:

Notification number.

Create Work Order Create PM Order directly with IW22 Maintenance

from Notification. Notification. Planner

Input:

Order type.

Enter planning data. Planning data like technical IW32 Maintenance

object, operations required with planner
components, tools, permits etc.

Input:

Order number.

Execute controlling Execute Controlling functions like IW32 Maintenance

functions. material availability check, planner
capacity leveling etc.

Input:

Order number.
Assign /Issue Permit Issue of required permits for IW32 Manager
execution of tasks

Inputs:

Maintenance order number

Release order Release the order to create IW32 Maintenance

reservation for new spare planner
part/equipment

Create PO for Create PO for the External ME21N Purchasing Officer

External Services Services Procurement if the
Procurement Maintenance work requires these
resources.

Inputs: Service PR Number

Goods Issue for Issue new spare part MIGO Store in charge
Equipment /Spare
parts Input:

Reservation
number,plant,storage location

Order confirmation Confirmation of the IW41 Maintenance

activities/reservation planner

Input:

Technical Technical Completion is a IW32 Maintenance

Completion of Order function that is performed for a Planner
maintenance order if the planned
tasks it contains have been
performed and confirmed.

Input:

Order

Order Settlement Settlement of order to material KO88 Maintenance

planner
Input:

Order number, settlement period