Transcript Functional Location BOM

PM
Master Data 2
Course Objective
Understand the concepts of
Bills Of Material (BOM)
Work Center
Task List
Above tasks are divided in to three parts
from Part 1 to Part 3
Part 1 – BOM Course titles
Bill of Material
Equipment BOM
Functional Location BOM
Material BOM
BOM Course Objectives
 Describe the concepts
and criteria for:
 Functional Location BOM
 Equipment BOM
 Material BOM
 Understand BOM usage
for the planning of
maintenance activities
Bill of Materials
A Bill of Material (BOM) is a
structured list of components
that make up an object.
A BOM is used to represent the
structure of an object during
spare part planning.
Assignment of Bill of Material
 Two ways of assigning BOM to a
technical object are:
 Direct assignment or
 Indirect assignment
 Direct assignment is done through the
creation of an Equipment or Functional
location BOM. The BOM is created
specifically for that technical object.
 Indirect assignment is done through the
creation of a Material BOM that is entered
into the Construction type field in the
technical object record.
Part 1 – Course titles
Bill of Material
Equipment BOM
Functional Location BOM
Material BOM
Equipment BOM
 Direct assignment of the bill of materials
to the equipment record.
 List of components (stock and nonstock) that are regularly used during the
maintenance of the equipment.
 Will be created when:
 A new equipment record is created.
 An existing equipment record
requires a spare parts list.
Creating Equipment BOM
 The BOM is created with reference
to an individual piece of equipment.
 Components are specific for the
individual piece of equipment.
 Enables material planning in
maintenance orders and task lists to
be performed more effectively.
 Multiple BOM for an equipment can
be created.
Maintaining Equipment BOM
 Updating equipment BOM ensure data
integrity
 Equipment BOM are changed when:
 Additional component required
 Existing component needs to be
removed or substituted or quantities
changed
 BOM header description needs to be
changed
 Equipment BOM are deleted when:
 Equipment master record flagged for
deletion
Part 1 – Course titles
Bill of Material
Equipment BOM
Functional Location
BOM
Material BOM
Functional Location BOM
 Direct assignment of the bill of materials to
the functional location.
 List of components (stock and non-stock) that
are regularly used during the maintenance of
the functional location.
 A functional location BOM is used in the
following situations:
 When identical equipments are installed.
 Where common spares used for more
than one equipment (Coupling used by
motor and gearbox).
Creating Functional Location
BOM
 The BOM is created with reference to an
individual functional location.
 Components are specific for the individual
functional location or equipment installed at
the location.
 Enables material planning in maintenance
orders and task lists to be performed more
effectively.
 A functional location BOM can contain
material BOM.
Maintaining Functional Location
BOM
 Functional location BOM are changed when:
 New component required
 Existing component needs to be removed or
substituted or quantities changed
 Functional location BOM are deleted when:
 Functional location master record flagged for
deletion
 Functional location BOM created incorrectly
 Updating functional location BOM ensures that
accurate information is available for planning
Part 1 – Course titles
Bill of Material
Equipment BOM
Functional Location BOM
Material BOM
Material BOM
 A material BOM is created with a direct link
to a material master record.
 Contains a list of stock or non-stock
components
 Can be used by multiple technical objects.
 A material BOM is used in the following
situations:
 For assemblies
 For identical equipment that have a
material number.
Material BOM cont..
 Enables material planning in
maintenance orders and task
lists to be performed more
effectively.
 A material BOM can contain
other material BOM.
 Can be created with reference
to another material BOM.
Transaction code tips
IB01 – Create Equipment BOM
IB02 – Change Equipment BOM
IE02 – Link Material BOM to Equipment
IB11 – Create Functional Location BOM
IB12 – Change Functional Location BOM
MMP1 – Create PM Assembly
CS01 – Create Material BOM
CS02 – Change Material BOM
Part 2 – Work center Course titles
Work center over view
Work center Maintenance
Work center hierarchy
Course Objectives Work
Centers
 Discuss the concepts of work
centers
 Understand the different work
center categories and its
usage.
 Discuss the concepts of a work
center hierarchy
 Create and manage work
centers
Work Centers
 A labor work center is a grouping
of craftsmen that perform
maintenance work.
 A work center can also represent
a piece of equipment used in
maintenance operations
 The work center is used to plan
maintenance activities in task
lists and maintenance orders.
Work Centers Data
 Default values maintained in the work
center data are copied to the PM
order.
 Costing information used to
determine the activity cost.
 Capacity details are used to schedule
the operation.
 Operation can be scheduled using
scheduling information
Part 2 – Work center Course titles
Work center over view
Work center
Maintenance
Work center hierarchy
Creating Maintenance Work
Centers
 When creating a work center, the work
center category must be specified.
 Work center can be created by
copying from existing work center.
 The information from the existing work
center is copied into the new work
center and can be changed as
required.
 Work center can be renamed
Main Work Center
 A main work center will be
used in the main work center
field for the following objects:





Task lists
Maintenance orders
Maintenance notifications
Equipment
Functional locations
 Used within capacity
evaluation to aggregate
operational work centers.
PM Machine Work Center
 Represent fixed machines and
fleet objects that need to be
scheduled and costed in
maintenance orders.
 PM Machine work centers are
used to assign against
operations in maintenance
task lists and orders.
 Used within capacity
evaluation.
Work Center Capacity
 The capacity of a work center is the total number
of hours per day a work center can perform
maintenance activities.
 Commonly used three work center capacity
categories are:
 001 Machines
 002 Labor
 022 Pooled capacity
 For categories 001 & 002 the capacity is defined
within the work center.
 Pooled capacity is created outside the work
center and assigned to the work center.
Pooled Capacity
 Allows you to assign multi-skilled
technicians to more than one work
center.
 The capacity of the multi-skilled
technicians is created as a pooled
capacity separate to the work
centers.
 The pooled capacity is then
allocated to all relevant work
centers.
 When maintenance activities are
assigned to the work centers the
pool capacity is used in capacity
evaluation and leveling reports.
 If a change is made to the pool
capacity it is reflected in all
relevant work centers’ available
capacity.
Part 2 – Work center Course titles
Work center over view
Work center Maintenance
Work center hierarchy
Work Center Hierarchy
 Work centers are grouped together into a work center
hierarchy.
 Each level within the hierarchy will be represented by a
work center(s). Can consists of 3 levels.
 Hierarchies are used in capacity planning to cumulate
available capacity and capacity requirements.
 Can consist of 3 levels.
 The lowest level of the hierarchy will consists of
operational work centers.
 The second lowest level of the hierarchy will consists of
main work centers.
 Hierarchy work centers are used in the first level of the
hierarchy.
Transaction code tips
IR01 – Create Work Center
IR02 – Change Work Center
CR11 – Create Capacity
CR22 – Change Hierarchy
Part 3 – Task List Course titles
Task List over view
Equipment Task List
Functional Location Task
List
General Task List
Course Objectives Task Lists
 Describe the concepts and criteria for:
 General Task Lists
 Equipment Task Lists
 Functional location Task Lists
 Understand usage of maintenance task lists
for the planning of maintenance activities.
 Understand usage of maintenance task lists
are used within preventive maintenance.
Maintenance Task Lists
A maintenance task list is a pre-defined
sequence of maintenance events that are
performed repeatedly within a company.
Maintenance Task List
Task lists are used for preventive and corrective maintenance
Task lists are copied into the Maintenance order
Maintenance Task List Structure
Task List Header
Description
General data
Task List operation
Operation sequence
Standard expected hours
Component / PRT assignment
Required components can be assigned
PRT can be assigned to an operation
Task List Header Detail
 Task list are created for each plant.
 Each task list will belong to a task list group
and will have its own counter number.
 Statuses are used to control the creation and
use of the task lists.
 A maintenance strategy is entered if the task
list is created for use within a strategy
controlled maintenance plan.
 The profile is used when creating a task list to
default details into the task list.
Task List Operation Detail
 The operations of the task list detail the
activities to be performed within the task list.
 A task list can contain multiple operations.
 There are two types of operations:
 Internal Processing Operations
 External Processing Operations
 Depending on the operation control key the
operation is planned differently.
Internal Processing Operations
 Following are the required details to create an
internal processing operation:
 Work center
 Control key
 Operation description
 Work effort
 Number of people
 An operation can only have one work center
assigned.
 Additional work centers can be added to add
additional operations.
External Processing Operation
 To plan maintenance activities for external processing use:
 Defined Control key indicating it as external operation.
 This control key will allow you to specify services using service master
records for work agreed between the vendor and SABIC. (e.g. motor
overhaul, motor rewiring) or using text services
 Purchasing information containing following info must be entered.






Planned delivery time
Cost element
Material group
Vendor
Purchasing Group
Purchasing Organization
Service Specification
 Against the external operation
the individual services are
planned.
 Service master records or text
services are used to plan the
required activities.
 For each service the quantity,
unit of measure and price is
required.
Task List Operation Detail
(Cont.)
 It is possible to assign the following items for
an operation:





Components
Production Resource Tools
Maintenance Packages
Relationships
Inspection Characteristics
 Additional text to describe the operation can
be entered using long text for an operation.
Production Resource & Tools
 If a PRT is required to
complete an operation the
PRT is planned against the
operation.
 The required usage and PRT
control key are entered for
each PRT assigned to the
operation.
Maintenance Packages
 If the task list is used for a strategy based
preventive maintenance plan, the strategy is
entered on the task list header.
 One or more maintenance packages are
assigned to the individual operations.
 The maintenance package defines when the
operation is to be performed i.e the frequency.
 When the maintenance package falls due, the
operations assigned to the package will be
included in the maintenance order.
Part 3 – Task List Course titles
Task List over view
Equipment Task List
Functional Location Task
List
General Task List
Equipment Task Lists
 Created specifically for a piece of equipment
and is unique for that piece of equipment.
 It is possible for an equipment to have more
than one task list created.
 Each task list is given a counter number to
identify it.
 Equipment task list can be created by copying
and required data can be changed.
Part 3 – Task List Course titles
Task List over view
Equipment Task List
Functional Location
Task List
General Task List
Functional Location Task Lists
 Created specifically for a functional location
and can only be used for that functional
location.
 It is possible to have more than one task list
created for a functional location.
 Each task list is given a counter number to
identify it.
 When creating a functional location task list is
possible to copy from an existing task list and
make the necessary changes.
Part 3 – Task List Course titles
Task List over view
Equipment Task List
Functional Location Task
List
General Task List
General Task Lists
 Used as a common task list for equipment or
functional locations. Not specific to any
equipment and functional location
 Logical naming conventions are given to
general task list group names. Can also be
identified with group name and counter
 Each task list within a general task list group
has a unique counter.
 Used for preventive, corrective and
refurbishment maintenance.
Transaction code tips
IA01 – Create Equipment Task List
IA02 – Change Equipment Task List
IA11 – Create Functional Location Task List
IA12 – Change Functional Location Task List
IA05 – Create General Task List
IA06 – Change General Task List
Summary
You should have understood the concept of
BOM – Bill Of Material
Work Center
Task List
PM
Technical Objects
Course Objectives
 Understand the concepts of following:
Functional Locations
Equipment
Fleet Objects
Production Resource Tools
Serial Numbering
Warranties
Counters and Measuring
points
 Create Technical objects hierarchy
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Structure of Technical Object

Maintenance Plant
 A maintenance plant is a place
where operational systems of a
company are installed which
requires periodic maintenance.
 Each manufacturing or
maintenance setup will form a
separate maintenance plant.

Planning Plant
 A maintenance planning plant is
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Functional Locations
 Functional location
A functional location is a
position within the hierarchical
structure and represents a
location where technical objects
can be installed.
 Functional Location Structure (FLS)
A logical break down of a plant
or section of a plant that allows
both operations and
Structure of IND6 (FLS)
 Plant structure is broken into four
parts:
AAZZ-NN-ZZZZZ-ZZZZZ
1
2
3
Level 1:
Level 2:
Level 3:
Level 4:
4
Plant & Processing Area
Processing Lines / Facilities
Major Processes / Facilities
Sub-Processes / Facilities
 It is suggested to use standard abbreviations for the
naming convention for each level.
Structure Example (FLS)
Level 1
IND6
Production of
Product A
IND6-01
Level 2
Level 3
Level 4
Line 1
IND6-01-PPS01
Piping System
IND6-01-FPS01
Fire Prevention
Systems
IND6-01-PTS01-MAC01
Machine 1
IND6-02
Line 2
IND6-01-PTS01
Production system
IND6-01-PTS01-MAC02
Machine 2
IND6-03
Line 3
Functional Location Master
Functional Location Master data contains
General Data – reference data and manufacturer data
Location
-- Location data, address
Account data -- Cost center, company code
Structure
-- Functional location structure info.
Data links
-- Data link to master records.
E.g. Measuring point
Functional Location Category
 Initially functional locations and
structures are part of PM master
data.
 The functional location category
controls the layout of the
functional location master record.
 The functional locations can be
broken up into the different
categories:
Creating Functional Locations
 New functional locations are created
when:
 A new plant is built
 An existing plant is expanded
 Functional location can be created by
copying from an existing functional
location.
 Copied details from the existing
functional location into the new
functional location can be changed.
Functional Location Maintenance
 A functional location will need to be maintained
when:
Functional location is activated
Maintenance responsibility
changes
Financial responsibility changes
Functional location is no longer
required
 When several functional locations are to be
changed, the Change Functional Locations Using
List Editing transaction(IL05) can be used.
Transaction code tips
IH01 - Display Functional Location Structure
IL01 – Create Functional Location
IL04 –Create Functional Location using
List Editing
IL02 – Change Functional Location
IL05 – Change Functional Location using
List Editing
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Equipment
 Equipment is an
individual physical
object.
 It is maintained as an
independent unit to
track maintenance
costs and technical
history.
Equipment Record
Equipment record represents physical object in the plant.
Equipment can be installed and dismantled from functional locations.
Maintenance is planned and executed with equipment
Maintenance records are kept against each equipment
Installing & Dismantling of
Equipment
Equipment can be installed in the functional
location at right level
Equipment can be installed only at ONE location
at a time
Installing and dismantling indicates the physical
movement of equipment
Measuring point and counter transfers are
broken during installation or dismantling
Equipment Record info
Master record contains following information



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

Equipment general data
Equipment location
Equipment usage
Equipment classification
Serial number data
Classification
Measuring points and counters
Warranties
Equipment record can be linked to an asset number
Equipment Category
 Equipment records can be broken
up into the categories.
 Example of equipment categories
 B for Safety
 K for Electrical
 F for Fleet
 E for Instrument
 M for Mechanical
 P for Production Resources
& Tools
 The equipment category controls
the layout of the equipment
record.
 The equipment numbering can be
internal generated numbering.
Equipment Classification
 Helps to organize equipment
master records and describe them
in a structured way.
 A class hierarchy will help to
assist in the search for equipment
classes.
 Only required equipment can be
classified.
 The class can be used to search
for equipment master records.
 Each class will contain several
characteristics.
 The characteristics are used to
store specific information against
the equipment master records.
Characteristics
 Each class will contain a required
characteristics: Example
 Data Sheet Code
 Drawing code
 Instrument Drawing code
 Additional characteristics can also
be included in the class.
 A value should be entered for
each of the characteristics.
 The characteristic data can be
viewed from within the equipment
master record.
Equipment Statuses
User status and system status helps to manage equipment
System status is always attached to the equipment
User status can be attached to an equipment as optional
E.g. Available status of equipment system status will allow it to install
Equipment Dismantling
 Equipment can be dismantled from the functional
location when it is required. E.g. removed from the
functional location.
 Upon dismantling the equipment the following step
should be taken into account:
 Update the account assignment (i.e. cost center)
 Update the user status (if applicable)
 Deactivate maintenance plans (if applicable)
 A usage period will be created upon dismantling.
 The system status will change to AVLB for
‘Available’.
Equipment Installing
 An equipment can be installed at a functional
location or a superior equipment.
 Upon installing the equipment the following
step should be taken into account:
Update the account
assignment (i.e. cost center)
Update the user status (if
applicable)
Activate maintenance plans (if
applicable)
 The system status changes to INST for
Equipment Scraping
 When scrapping an equipment the following steps
should be performed.
Delete any task lists, BOM and
measuring points.
De-activate maintenance plans (if
applicable)
Equipment dismantled
Update the account assignment
(i.e. cost center)
Update the user status to SCRP
for ‘Scrapped’
Transaction code tips
IE01 – Create Equipment
IE02 – Install Equipment
IE02 – Change Equipment
IE05 – Change Equipment using List Editing
IE02 – Dismantle Equipment
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Fleet Objects
A fleet object is an
equipment that moves
from one location to
another to perform
maintenance functions.
Example:
Forklifts
Trucks
Fleet Objects
 A fleet object is a special category of equipment.
 It has the same functionality as a normal piece of
equipment.
 Includes additional tabs to record fleet
information:
 Identification details
 Dimensions
 Weight specifications
 Load specifications
 Engine details
 Fuel and lubricant details
 Need not be installed at a functional location.
Fleet Object
 A fleet object can also be created
as a PRT and a work center.
 To create a PRT record for a
Fleet object, maintain entries
in the PRT tab of the Fleet
object record.
 A fleet object as a work center
allows:
 Scheduling of fleet object
 Costing
 A fleet object as a PRT allows the
fleet object to be assigned to an
operation within the order.
Creating Fleet Objects
 A fleet object master record is created to
represent a mobile device that requires
maintenance history to be recorded.
 A new fleet object master record is created
when;
 A new fleet object is purchased or
 An existing fleet object replaced.
 During the creation of the fleet object it is
possible to:
 Create measuring points and counters
 Assign warranties
Fleet Object Counters
 Counters can be used for fleet
objects to assist in:
 Calculating fuel and oil
consumption
 Determining replacement or
maintenance of object
 For each individual fleet object
counters can be created using
measurement positions.
Transaction code tips
IE31 – Create Fleet Object
IE02 – Change Fleet Object
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource
Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Production Resource & Tool
 A PRT is a special resource required
by a crew to perform a maintenance
task.
 A PRT could be a special tool.
Production Resource & Tool
 A PRT equipment is a special
category of equipment.
 It has the same functionality as a
normal piece of equipment.
 Includes an additional tab for PRT
information:
 Usage details
 Default values
 Ability to lock
 An equipment PRT can be
planned as a requirement against
an operation within a maintenance
order.
 Maintenance can be performed
and history recorded for a PRT
equipment.
Creating PRTs
 A PRT equipment is created for an
object when it needs to be
planned within a maintenance
order.
 PRT not installed at a functional
location.
 During the creation of the PRT
equipment it is possible to:
 Create measuring points and
counters
 Assign warranties
Transaction tips
IE25 – Create PRT Equipment
IE02 – Change PRT Equipment
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Serial Number

Serialization is the assignment of a
unique SAP serial number to a
Material and Equipment master
record.

The Serial number is the common
link between Material number and
Equipment number.
Equipment Serialization
 New serial number will be
given by warehouse for new
material.
 Equipment record is created
automatically.
 The serial number will always
stay unique to the equipment
Transaction code tips
IE02 – Maintain Serialization for Equipment
IQ09 – Display Serial Numbers using List
Editing
MMBE – Display Serial Numbers from
Stock Overview
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Warranties
A warranty is given to the
customer by a vendor or
manufacturer.
This assures to the customer
that the product is reliable and
free from known defects.
It also assures customer to
undertake the responsibility
for any defect within
stipulated period
Warranties
 Two types of warranties available:
Inbound -- Vendor / Manufacturer
Outbound -- Customer
 Both a Vendor/Manufacturer and a Customer
warranty can be assigned to an equipment.
 A warranty can be assigned to the equipment by:
Entering the warranty start or
finish dates directly in the
technical object record or
Assigning a master warranty
 Warranties that are maintained without a master
warranty on the equipment record can only be time
based.
Master Warranty
 To define more complex
warranties for an equipment
a master warranty can be
used.
 A master warranty is broken
into three parts.



Header
Item
Counter
Master Warranty Counters
 Warranty counters are used to define the
conditions and requirements for the master
warranty.
 Warranty counters can be:
 Time based
 Performance based counters
 Combination of both
 If the master warranty contains more than
one warranty counter an “and/or”
relationship must be entered.
 If performance based counters are used
within the warranty master the
corresponding counters must be first
created for the technical object.
Master Warranty (Cont.)
 When assigning a master warranty to
an equipment a warranty start date
must be entered.
 Once a master warranty is assigned to
an equipment record a warranty check
is performed each time a maintenance
notification or order is created against
the equipment.
 The user can then investigate if the
maintenance activities are covered by
the warranty and take the necessary
actions.
Transaction code tips
IE02 – Maintain Time Based Warranty for Equipment
BGM1 – Create Master Warranty
BGM2 – Change Master Warranty
IE02 – Assign Master Warranty to Equipment
Course Direction
Technical Objects
Functional Locations
Equipment
Fleet Objects
Production Resource Tools (PRT)
Serial Numbering
Warranties
Measuring Point
Measuring Points
 A measuring point is a physical or logical
position for a technical object (Equipment)
where a condition can be recorded.
 A counter is a kind of measuring point that
accumulates performance based readings.
 A Technical object (equipment) can have
multiple measuring point
Measuring Points
 Measuring points and counters are created for
technical objects to record a condition for the
technical object at a given point in time.
 Examples of the type of conditions:
 Temperature as measurement points
 Flow rate as counters
 Operating hours as counters
 The measuring point or counter defines the
location and the specific condition to be recorded
for the technical object.
 Each measuring point or counter will have its own
ID number.
Measuring Points
A technical object can have multiple
measuring points and counters.
Use of Measuring points
 Measuring points can be used for condition
monitoring of a piece of equipment.
 Upper and lower limits can be set for a
measuring point.
 corrective maintenance notification is
automatically created, If a measurement
reading is outside the tolerance limit.
Counter Measuring Points
A counter is used to record continuous
values. (e.g accumulative values, run time
hours)
Counters can be used in maintenance plans
to schedule preventive maintenance.
An annual estimate is entered for a counter.
Transaction code tips
IK04 – Create Measuring Point for Object
IK05 – Change Measuring Point for Object
IK08 – Change Measuring Points using
List Editing
IK31 – Create Measurement Reading Entry
List
Summary
 Understood the concepts of following:
Functional Locations
Equipment
Fleet Objects
Production Resource Tools
Serial Numbering
Warranties
Counters and Measuring
points
 Should be able to create Technical objects