Process Review

Plant Maintenance
Master Data Order Creation & Processing Preventative Maintenance Gage Calibration

Confidential Copyright 2007 Deere & Company Worldwide Agricultural Division

Chapters
The topics presented in this course include:
Technical Objects
Functional Locations Equipment

Maintenance BOMs
Material BOMs Equipment BOMs

Work Centers Document Links

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Functional Location
Functional location should represent the work team or physical location within a plant where maintenance tasks are performed. Functional locations are organized in a hierarchy. Work Orders and Preventative Plans may be created for Functional Locations (i.e. Facilities) Equipment can be assigned to a functional location. Functional locations use a defined naming convention called a structure indicator. For example the structure could be:
Plant > Site > Department/Facility > Equipment Type
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Functional Location
Functional locations can be used to do cost analysis.
Maintenance costs for equipment installed at a functional location will be rolled up to that functional location allowing cost analysis at the highest levels.

Functional location master can contain:

Location Maintenance Plant Location Plant Section Organization Company Code Cost center Planner Group

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Creating a Functional Location IL01

Structure Indicator The new functional location will inherit the values of its superior functional location as long as the structure is the same.

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Ottumwa Facilities Structure

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Ottumwa Installed Equipment Structure

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Ottumwa Miscellaneous Locations

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Equipment Creating of Required When:

Preventative Maintenance or Repair type orders need to be written against it. Maintaining specific information for equipment:
Manufacturer/Vendor information (model, serial, etc) Acquisition value / date etc. Warranty

The costs and reasons for performing maintenance needs to be monitored and reported. Functional location assignment history is needed

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Creating Equipment

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Maintenance BOMs
BOMs are a list of the components (spare parts) making up a technical object (equipment) or an assembly (IBAU material). Used for Spare Parts (materials) Planning
For orders or task lists, you can identify and plan to use spare parts that exist in the bill of material.

The three types of Maintenance BOMs are:

Functional Location BOMs Equipment BOMs Material BOMs

Parts purchased for equipment will not be automatically added to BOMs.

Maintain the BOM manually to add or delete any material.
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Work Centers
Skilled trades group that carry out maintenance work Uses of Work Centers:
Operations within a work order specify work centers necessary for the task Scheduling Work center Working times and shifts impact the work order start dates. Costing Costs are calculated based from the cost center and activity type assigned to the work center. Capacity Planning based on the number of people and shifts assigned to the work center. Linking to HR Employees in HR can be linked to work centers.

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Order Creation & Processing

General Create and View Plant Maintenance Work Orders

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Creating & Viewing Maintenance Work Orders

Why do we create work orders? Track cost and history Improve machine reliability and uptime Prioritization of work order backlog queue

Examples of when you might create a work order Machine down Request project work (Ex: new guard rail) Replace a light

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Basic steps to create an EasyEntry Work Order

Execute ZI_EASYENTRY

Creating Easy Entry WO

Step 1 Step 2 Step 3 Step 4 Step 5 Execute ZI_EASYENTRY Select Equip or FL Select Order Category Selections from 4 menus Add WO description; Review; Save

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Basic steps to create an EasyEntry Work Order Select Equipment or Functional Location
Step 1 Step 2 Step 3 Step 4 Step 5

Creating Easy Entry WO

Execute ZI_EASYENTRY Select Equip or FL Select Order Category Selections from 4 menus Add WO description; Review; Save

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Basic steps to create an EasyEntry Work Order Step #3 Select Order Category
Step 1

Creating Easy Entry WO

Execute ZI_EASYENTRY Select Equip or FL Select Order Category Selections from 4 menus Add WO description; Review; Save Step 2 Step 3 Step 4 Step 5

1. For the Order Category section, Repair is the default (can only select one)

2. Each radio button is associated with a specific order type.

Order Type ##M3

Planned / Unplanned Planned

##M1
##M3 ##M6

Unplanned
Planned Planned

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Basic steps to create an EasyEntry Work Order

Selections from 4 menus

Creating Easy Entry WO
Step 1 Step 2 Step 3 Step 4 Step 5 Execute ZI_EASYENTRY Select Equip or FL Select Order Category Selections from 4 menus Add WO description; Review; Save

Menu #2: Electrical control objects

Menu #1: Major objects for a Laser

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Basic steps to create an EasyEntry Work Order Step #4 Selections from 4 menus
Creating Easy Entry WO
Step 1 Execute ZI_EASYENTRY Select Equip or FL Select Order Category Selections from 4 menus Add WO description; Review; Save

Menu #3: List of problem catalogs for a Laser

Step 2 Step 3 Step 4 Step 5

Menu #4: List of more detailed electrical problems

Note: Each Equipment or Functional Location can provide different menu selections through a Catalog Profile

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Basic steps to create an EasyEntry Work Order Step #5 Add WO description; Review; Save
Step 1 Step 2 Step 3 Step 4 Step 5

Creating Easy Entry WO

Execute ZI_EASYENTRY Select Equip or FL Select Order Category Selections from 4 menus Add WO description; Review; Save

1. Type in work order description

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Creating EasyEntry Work Orders Normal Scenarios

More on a Functional Locations Used by Plant Maintenance module to represent an area, location, or process A piece of master data similar to an equipment master Equipment can be associated (installed) to a Functional Location

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Creating EasyEntry Work Orders Normal Scenarios

It can represent a department

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Creating EasyEntry Work Orders Normal Scenarios

It can represent a building

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Searching for Maintenance Work Orders

Work Order Status

REL Released Labor & Materials can be charged

PCNF
CNF TECO CLSD

Partially Confirmed
Finally Confirmed Technically Complete Closed

Labor Charged; work remaining

Labor Charged; all work complete Work Order is complete Work Order closed by batch job if TECO > 90 days

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Searching for Maintenance Work Orders

Execute IW39

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Searching for Maintenance Work Orders

IW39 Example #1: List of open work orders created by RACF CS70735, for the Davenport Works (DW01)

For all open orders (status REL)

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Searching for Maintenance Work Orders

List of open work orders for equipment 114164 at the Davenport Works

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Searching for Maintenance Work Orders

IW39 Example #2: List of open work orders for equipment 114164 at the Davenport Works

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Order Processing

Plant Maintenance Execution

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Plant Maintenance Execution

Work Order Types Work Order Cycle processes and transactions Work Order Selection Work Performed

Charging Labor and Closing

Emergency / Breakdown Orders Sub-Order Work Order (IW36) Summary of using IW37

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Work Order Cycle

Work Order Cycle

Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Order Selection Find Work Order

Work Order Cycle

Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Order Selection Find Work Order

IW39 Display PM orders: Selection of Orders

Display Orders Order Oper IW39 IW49

Change IW38 IW37

IW37 Change Operations: Selection of Order Operations

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Work Order Cycle Work Order Selection Find Work Order

IW37 Example #2: List of DW01 open CFM1 Emergency / Breakdown work orders for equipment 121796

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Work Order Cycle Work Order Selection Find Work Order

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Work Order Cycle Work Order Selection Arriving on Work Order

Work Order Cycle

Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Order Selection Arriving on Work Order

From IW37, enter work center and plant

Select the line with your work order

REL

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Work Order Cycle Work Order Selection Arriving on Work Order

Confirmation Screen Enter SAP Personnel Number Save

Zero hours

Back on the IW37 list, after refreshing New status of PCNF, and zero actual work hours

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Note: It is the combination of status PCNF and zero actual work hours that tells us someone has arrived on the work order

Work Order Cycle Work Order Selection Assigning Work Order

Work Order Cycle

Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Order Selection Assigning Work Order

IW37 list of work orders, select line with your work order Click the Order button

Order screen

Add the SAP ID of the employee to be assigned to this work orderthen Save

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Work Order Cycle Work Order Selection Assigning Work Order

Back to the IW37 list of work order operations (after refresh)

First operation now has SAP ID 614125 assigned to it

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Work Order Cycle Work Order Selection WO Print / Print Preview

We will now show how to print preview a work order, and direct it to a printer.
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Order Selection WO Print / Print Preview

IW37 select line

Order button

Order screen

Menu: Order Print Order

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Work Order Cycle Work Order Selection WO Print / Print Preview

default line selected is the 2010 line This will print to the printer designed for the skilled trades work center

Or use OVER to select a printer manually

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Work Order Cycle Work Order Selection WO Print / Print Preview

Print Preview

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Work Order Cycle Work Performed Adding an Operation

We will now review the process for adding another operation to a work order.
Work Order Cycle
Production Work Order Creation

DW

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Adding an Operation

IW37

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Work Order Cycle Work Performed Adding an Operation

Enter description for the new operation

Enter long text if desired

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Work Order Cycle Work Performed Adding an Operation

To assign a person to each operation using their SAP HR ID, select both operations

Navigation arrows

Add the personnel number (SAP HR ID) for each operation

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Work Order Cycle Work Performed Adding an Operation

IW37 we do not see the new operation of 0020 Filtered on work center M90-709and E90-703 was added to oper 0020

Adding work center E90-703 to the filter

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Work Order Cycle Work Performed Material or Equip BOM

2 recommended ways to find an indirect part. Preferred method viewing a material or equipment BOM
Work Order Cycle
Production Work Order Creation Charge Labor & Close

Work Order Selection

Work Performed Add operation

IW37 IW32

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Material or Equip BOM

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Work Order Cycle Work Performed Material or Equip BOM

Environment BOM item Material stock

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Work Order Cycle Work Performed Material or Equip BOM

Double click on the Material

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Work Order Cycle Work Performed Material or Equip BOM

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Work Order Cycle Work Performed Material or Equip BOM

To check stock, you can click the Material Availability button

Another way to check stock is the Storage Location field matchcode

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Work Order Cycle Work Performed Material or Equip BOM

Difference between a material BOM and an equipment BOM?

Equipment BOM Material is assigned directly to the equipment

Equipment BOM

Material BOM material is assigned to a Construction Type The Construction Type is assigned to the Equipment

Material BOM

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Work Order Cycle Work Performed Find Material (ZM_MAT_STOCK)

Find a part using transaction ZM_MAT_STOCK
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Find Material (ZM_MAT_STOCK)

ZM_MAT_STOCK

Material Types
ERSA - Spare Parts Repair parts; belts; bearings; pumps HIBE Operating Supplies Office / cleaning supplies FHMI Production Resource & Tools Grease; perishable tools, gages; fixtures; dies
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Work Order Cycle Work Performed Find Material (ZM_MAT_STOCK)

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Work Order Cycle Work Performed Goods Issue

Getting a repair part out of a crib.
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Goods Issue

From IW37, select WO and click on the Individual confirmation button

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Work Order Cycle Work Performed Goods Issue

Click the Save button

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Work Order Cycle Work Performed Goods Issue

SP01 to preview the pick ticket

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Work Order Cycle Work Performed Goods Issue

Warehouse Part description Part number

Storage Type

Bin Location

Work Order Number

Storage Type Description Barrel Crib Central Crib Electrical Crib 300 Old Shot Blast Code BRL CTL ELC OSB

Pipe Fitters Crib

Vertical Towers

PFT
VRT

Transfer Order Number

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Work Order Cycle Work Performed Goods Issue

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Work Order Cycle Work Performed Req (Unnumbered Non-Stock)

Creating a requisition for a part that does not have a material master, and is not stocked.
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Req (Unnumbered Non-Stock)

N for Non-Stock in the Item Category (IC) field

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Work Order Cycle Work Performed Req (Unnumbered Non-Stock)

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Work Order Cycle Work Performed Req (Unnumbered Non-Stock)

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Work Order Cycle Work Performed Req (Numbered Non-Stock)

Requisition for an indirect part with a material master but is not normally stocked.
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Req (Numbered Non-Stock)

Note: This process can be used for a part that 1. Has a material master and is not stocked 2. Is normally stocked, but you want to order some without touching the crib inventory

N for Non-Stock in the Item Category (IC) field

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Work Order Cycle Work Performed Req (Numbered Non-Stock)

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Work Order Cycle Work Performed Req (Numbered Non-Stock)

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Work Order Cycle Work Performed Req (Services)

We will now review the process for creating a requisition for an outside contractor.
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition(Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Work Performed Req (Services)

Purchase Requisition from the work order for outside services

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Work Order Cycle Work Performed Req (Services)

Changing the control key to PM02 triggers the purchasing screen

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Work Order Cycle Work Performed Req (Services)

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Work Order Cycle Charge Labor & Close Charge Labor / TECO
Charge labor hours to a work order and technically complete (TECO)
Work Order Cycle
Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Charge Labor & Close Charge Labor / TECO
Charging labor to a work order

Enter your personnel number and hours then save After refresh

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Work Order Cycle Charge Labor & Close Charge Labor / TECO
Charge labor hours to a work order, immediately TECO (Technically Complete) it, and fill in the Cause catalog.

From IW37

Every operation on every work order must be Finally Confirmed upon completion This drives the Actual End date on the work order which will be used on metrics reports.
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Work Order Cycle Charge Labor & Close Charge Labor / TECO

Back on IW37

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Work Order Cycle Charge Labor & Close Viewing Confirmations

DW
Viewing Confirmations

Work Order Cycle

Production Work Order Creation

Work Order Selection

Work Performed Add operation

IW37 IW32

Charge Labor & Close

Find Work Order Create Work Order

Functional Location
ZI_EASYENTRY IW37 Report Variant

Repair Parts and/or Services Needed

Material or Equip BOM

Arrive on Work Order

IW37 IW41

IW32 Components List

Charge Labor / TECO

IW37 IW41 or IW42

Find Material
ZM_MAT_STOCK

Equipment

Assign Work Order

IW37 IW32

Goods Issue
IW37 IW41 Goods Movements

Viewing Confirmations
IW47

Work Order Print / Print Preview

IW37 IW32

Requisition (UnNumbered / Non-stock) Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)
IW32 Operations

Maintenance Request

Execution

Completion

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Work Order Cycle Charge Labor & Close Viewing Confirmations

DW

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Emergency / Breakdown ##M1 Work Orders

Emergency WO starts the breakdown clock IW42 to TECO the order and stop the breakdown clock ##M1 Work Order

Malfunction start date and times were populated based on when the order was created and saved.

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86

Emergency / Breakdown CFM1 Work Orders

After charging labor hours and completing the order (TECO)

DW

Malfunction End date and time and duration populated form completing the order

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Creating a sub work order

Scenario #1 for creating sub order:

DW

An emergency order (##M1) needs to be closed after the machine is up and running, but there is more work to do that should be associated with the original breakdown order.

The machine has been fixed, but before this order is closed create a sub-order for further needed work IW36

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Creating a sub work order

Scenario #1 for creating sub order:

An emergency order (CFM1) needs to be closed after the machine is up and running, but there is more work to do that should be associated with the original breakdown order.

Enter the description in the sub-order

Note: the status is Created (CRTD), click Put in Process to simultaneously REL and save

After saving, the superior order can be completed

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Order Processing

Preventative Maintenance

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Preventive Maintenance - Overview

Preventative maintenance is used to avoid breakdowns. It is the generic term for planned inspection and maintenance. Within Preventative Maintenance you can plan time and materials in advance. There are two types of maintenance planning:
Time Based maintenance is performed in specific time cycles, like monthly or semi-annually. Performance (Usage) Based maintenance is performed based on performance or usage readings of instruments that monitor the equipment. For example, a vehicle should be serviced every 100 usage hours; the usage information comes from an hour meter attached to the vehicle.
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Preventative Maintenance Master Data

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Maintenance Plan Definition

Description of the maintenance and inspection tasks to be performed on equipment or functional locations. The maintenance plans describe the dates and scope of the tasks. Contains the Maintenance Cycle or trigger when the maintenance must take place. The trigger can be time based or performance based. Maintenance plans must have at least one Maintenance Item. A Maintenance Item contains the technical object(s) and usually will be assigned a task list.

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Task List Definition

Describes the sequence of individual maintenance activities which must be performed. Task lists can be used for preventive maintenance and routine work. They can also specify the required material to carry out the operation as well as the time needed to perform the work. A task list can be created specifically for an equipment or functional location or can be general and reused on multiple equipment and/or functional locations.
Equipment Task List Functional Location Task List General Task List
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Measuring Points and Counters

Measuring Point physical or logical location where an equipment characteristic is measured. Counter tools that you use to represent the wear and tear of an object, consumption, or the reduction of an objects useful life. For example, an hour meter on a machine. Measuring Points use SAP characteristics to describe the attributes of measurement.
A characteristic describes what is being measured, and what the unit of measure is (i.e. Hour Meter in Hours or Caliper Reading in Inches).

Measurement Documents are created from Measuring Points. The results are stored in SAP and can be used to trigger maintenance.
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Flow for Time Based Planning

Need to Generate PMs for Equipment based on Time Does Equipment exist in SAP?

No

Yes

Create Equipment ( IE01)

Create Plan (IP41)

Create Task List (Optional) (IA01 - Equipment IA05 - General/Generic Task list IA11 - Functional Location task list)
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Flow for Usage Based Planning

Need to Generate PMs for Equipment based on Usage

Get Annual Usage Estimate

Get Latest Reading with Date

Does Equipment exist in SAP?

Yes

Create Measuring Point (IK01)

Create Measurement Document (IK11 Single Entry IK34 Collective)

Create Plan (IP41)

No Create Equipment ( IE01)

Create Task List (Optional) (IA01 for Equipment IA05 for General/Generic Task list)

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Time Based Preventive Maintenance Execution

Weekly Run of Batch Job (Auto)

Plan Triggered?

Yes

Work Order Created

No No Work Order

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Time Based Preventive Maintenance Execution How Time Based Preventative Work Orders are Scheduled
A Batch Job Runs Automatically
Orders are Created from Batch Job
Time is used as a trigger for order creation. The Cycle and Call Horizon in the maintenance plan is used to set the frequency and the call dates when the orders are created. Orders can be automatically printed to a specified printer.

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Usage Based Preventive Maintenance Execution

Enter Latest Reading Against Equipment / Measuring Point (IK11)

Weekly Run of Batch Job (Auto)

Plan Triggered?

Yes

Work Order Created

No No Work Order

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Usage Based Preventive Maintenance Execution

How Usage Based Preventative Work Orders are Scheduled

A Batch Job Runs Automatically

Orders are Automatically Created

Measurement document readings plus Measurement point annual usage estimates

The Trigger is when the estimated reading total meets or exceeds the cycle specified in the maintenance plan.

The Cycle in the maintenance plan is used to set the frequency.

The Call Horizon determines how early the order is created (default is 100% - or on time) The SAP system creates Call Dates from a combination of the readings and annual estimate. Orders can be automatically printed to a specified printer.

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Plan Scheduling Maintenance

A batch job automatically schedules the plan, but a tool is available to make changes to the schedule transaction IP10 (Schedule Maintenance Plan). You can use IP10 to:
Change the date of a call Skip a call Manually trigger a call

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Scheduling Overview
SAP offers following scheduling overviews:
Graphical (IP19)
Maintenance schedule Capacity load

As List (IP24)

Both views can display historical call information IP19 & IP24 can show the future order creation dates (call dates)

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Order Processing

Gage Calibration
Gage Calibration Overview Master Data Gage Calibration Processing

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Gage Calibration Process Flow

New Material Master required for gage? Yes
Create Indirect Material Master For New Gage MM01 MIS Group REVIEW CATEGORY

QM/PM - Gage Calibration Processing

Transactions in SAP
Gage's Status updated Calibrated Date updated
Auto Usage Decision Closes Insp. Lot & PM Order Updates Gage's Status & Plan's Calibrated Date QA11 Batch / QE REVIEW CATEGORY

No

Create Equipment Master For New Gage (with Object Type=G) IE01 MIS Group REVIEW CATEGORY Repair The Gage & Return To Calibration Area PM Order Inspector REVIEW CATEGORY Inspection Of Gage & Results Recorded On Characteristics (repair If Req'd) QE53 Inspector REVIEW CATEGORY

Equipment PM Task List Or General PM Task List IA01 / IA05 Gage Calb. REVIEW CATEGORY

Create PM Maint. Plan & Add Gage & Tasklist To Maint. Plan (Single Cycle) IP41 / IP02 Gage Calb. REVIEW CATEGORY

Batch Job Processing ... Search For Maintenance Plans Within Call Horizon ... Creates Inspection Lots & PM Orders Batch Job IP10 / IP30 REVIEW CATEGORY

Gage Calibration Report Next/ Last Calibratied Date Super/ Wage ZQGAGEREP REVIEW CATEGORY

Calibration Recording Sheet Gage Calibration Plans Characteristic Target Value(s) Recording Sheet ZQGAGERECSHT Inspector REVIEW CATEGORY

Create QE (MIC) Master Inspection Characteristic QS21 QM Master REVIEW CATEGORY Create Sampling Procedure For Gage PM Calibration QDV1 QM Master REVIEW CATEGORY Create Inspection Method QS31 QM Master REVIEW CATEGORY Create Quality Work Center For Gage Calibration CRQ1 QM Master REVIEW CATEGORY

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Gage Calibration Overview

Plant Maintenance Module
Manage master data Monitor maintenance cycles Calibrate

Quality Management Module

Inspection characteristics Inspection lots Results recording Usage decision

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Calibration Planning & Processing

PM Equipment Master (Gage) PM Maintenance Plan PM Equipment Task List

PM Scheduling

QM Inspection Characteristics

PM Maintenance Order QM Inspection Lot

QM Results Recording

QM Usage Decision

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Master Data
Gage Equipment Master Gage Task List Gage Maintenance Plan

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Functions of Equipment Master (IE01)

Contains link to Material Master (PRT) via the Construction Type field. Used to track Equipment (Gage) Keep record of calibration tasks Report and evaluate calibrations over time

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IE01 - Create Equip Master for Gage

Equipment number will be created by SAP system Valid On: Earliest date that the gage can be used Equipment category for Gages is

Equipment Master General Data (IE01)

1) Equipment number assigned by SAP system 2) Description describes the gage function/size

3) Long Text- allows are a more complete description of gage function/size

4) Object type- Catalog entry that best describes type of gage 5) Size/dimension- enter the size range for gage 6) Start-up date- date to start plan 7) Manufacturer dataoptional information that describes gage
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Equipment Master Location (IE01)

1) MaintPlant Physical Plant where gage is assigned Room- Department where gage is assigned Work Center- machine where the gage is located for production use

2) 3)

4)

Sort field- Location where the gage is stored. Cabinet/Draw/Compart ment, etc. Plant Section major building complex (DSS, FDRY, PEC, SPO & WAS) Not used at JDDMW

5)

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Equipment Master Organization (IE01)

1) Business AreaAppropriate division in Deere

2) Cost Center- Department that is responsible for Gage Calibration

3) Planning Plant- Plant responsible for the calibration of Gage 4) Planner Group- GAU Planner group that is responsible for Gage Calibration 5) Main WorkCtr- Main Work Center is area responsible for Gage Calibration
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Equipment Master Structure (IE01)

1. Funct. LocationPhysical location in plant.

2.

TechIdenNo- Equals the legacy gage number included from Data Loads with plant prefix Z (i.e. NX01X75010002)
ConstType- Link to the SAP Material Master of gage

3.

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Equipment Master PRT Data (IE01)

1) Task List Usage Set to 009 to make available to use on all task list types

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Equipment Numbers and Maintenance Task list (IA01) IE01 - PM Equipment Master (Gage) IA01 - PM Equipment Task List (characteristics to check)

IP41 - PM Maintenance Plan (calibration plan)

IE01- Create Equipment Master

+

IA01- Create Equipment Task List

+

IP41- Create PM Maintenance Plan

Gage Calibration Plan

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Function of Equipment (gage calibration) Task List (IA01)

Describes the steps (operations) for the calibration Inspection characteristics are assigned to the operation Inspection method can be assigned Inspection sampling procedure can be assigned.

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Maintenance Task List Structure (IA01)

Group: 12345

Equipment Task List Header:

Material assignment Usage
Task list header

Status

Operation
Inspection Char.
Sampling Procedure Inspection Method

Validity
Inspection Points

Operation: Control Key Description

Inspection Characteristic:
Operation

Inspection Method Sampling Procedure

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Maintenance Task List Header (IA01)

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Maintenance Task List Operation Overview (IA01)

Work Ctr- Assign the QM Work Center responsible for Gage Calibration
CTRL- Control Key; set to QM05 for Gage Calibration Insp Char- Use to create Inspection Characteristics (at bottom of screen)
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Maintenance Task List Characteristic Overview (IA01)

Quantitative Inspection Characteristic

Qualitative Inspection Characteristic

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Inspection Characteristics (IA01)

What do you inspect? Describe Inspection criteria Used for Planning Inspections Store Inspection specifications May be Qualitative (pass/fail) or Quantitative

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Characteristic Overview (IA01)

Inspection characteristic on a Task List, select the Pre-set Indicator for the type
of inspection characteristic. - Quantitative = D020

- Qualitative = D010 Setting preset indicator sets defaults in the Control Indicator screens for the
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characteristic. These can be changed if necessary.

Control Indicators Quantitative (IA01)

The inspection characteristic Preset-indicator type (Quantitative or Qualitative) determines what information is displayed.

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Control Indicators Qualitative (IA01)

The inspection characteristic Preset-indicator type (Quantitative or Qualitative) determines what information is displayed.

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Quantitative Inspection Characteristic (IA01)

Define Upper/Lower & Target specifications Assign sampling procedure SPC characteristic Summarized or single results recording Required/Optional Assign test equipment Track changes

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Quantitative Data (IA01)

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Sample & SPC (IA01)

The Control indicator for SPC was set, the Sample tab will require selection of SPC criterion. For gage calibrations, choose: 410 - Task list char./equipment, funct.loctn.
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Gage Calibration Maintenance Plan Calibration Cycle Frequency Start Date Call Horizon Gages to be Planned Task list for Gage assigned to Plan

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Maintenance Plan (IP41)

Cycle text = describe the cycle e.g. Annual calibration Dec (calibration is planned once/year in December) Cycle = a number Unit = period In the example, calibrations are 1/yr Equipment: the Gage that will be assigned to this Calibration plan When you add the equipment, information from the equipment master is brought into the screen. Plant, Work center, planner group Priority: A value must be selected to help define which gage(s) should be calibrated first Order type: MUST be AGM5 and MaintActivityType MUST be M19 Task List: Select Task List with binocular icon

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Gage Calibration Processing Call for Gage Calibration

Record Calibration Results Reporting Gage Usage Decision

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Calibration Process
Batch job Scheduled to run weekly Generate PM Order and Inspection Lot for each Gage due for calibration Calibration checked and results recorded Usage Decision Made

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Inspection Lot
An inspection lot is a request to a plant to carry out a quality inspection, in this case Calibration check on a Gage An inspection lot is created for a Gage, plant and inspection lot origin (source) Inspection lots are created automatically in the John Deere system The creation of Calibration inspection lots are triggered by release of a Gage Calibration Maintenance order

Gage Calibration due

Event
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Quality Inspection

Scenario Suspect Gage Out of Calibration

Run Report of Last/Next Calibration dates Create a Call for Calibration manually

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/DEEREAG/QMGAGEREP

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Manual Call for Calibration (IP10)

Is an Exception process Used to Call for a Gage to be calibrated outside of plan
Examples: Dropped the Gage Gage not repeating Indicator is sticking

Will be used in class to begin the Calibration cycle

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Scheduling a Manual Call of Gage (IP10)

Date will automatically be entered when the Manual Call is selected Manual Call of Gage will be created when the transaction is SAVED
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Calibration Schedule proposed (IP10)

The Calibration schedule is initially proposed. Nothing will happen until the plan is saved. When saved: A Maintenance Order will be created and released. (The Equipment Task list will be copied to the maintenance order.) When the PM Order is released, an Inspection Lot is created. Reminder: an Inspection Lot is a request to inspect something.
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Results Recording Quality Inspection (QE53)

The quality inspection takes place and results must be recorded for inspection characteristics.

During results recording, the user has access to histograms or control charts.

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Results Recording Worklist for Gages (QE53)

The Work list for Gages is hierarchical

Expand one Gage by level or all of them.

The 3rd level is the Gage master where you will record results

The Work list displays the PM Order number and Inspection characteristics assigned to the Equipment Task List

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Results Recording: Characteristics Overview (QE53)

Results are recorded in Result Column and valuated when Entered Specifications Column - contains the Lower & Upper limits

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Usage Decision (QA11)

A usage decision accepts or rejects the inspection lot.

If the lot is accepted, the Gage can be returned to Production.

Accept

If the lot is rejected, follow-up actions can be triggered and the Gage can be scrapped or sent for repair.
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Reject

Usage Decision: Characteristic Overview (QA11)

Usage Decision is made by selecting a Code (Accept or Reject) from the pull down list. Use the text field to enter the reaction plan and results if a gage fails calibration.

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Status Change for Object (QA11)

When

SAVING the usage decision, a popup window will appear asking you to confirm that the Gage is ready for use. If you click the box marked Change, the status will be set to Not ready for use Click Green Check mark to continue
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