1 About This Book

19

1.1 Target Audience

21

1.2 What This Book Can and Cannot Do

22

1.3 Structure of This Book

23

2 Plant Maintenance and SAP: A Contradiction?

27

2.1 Plant Maintenance Today: New Ideas Need New Space

28

2.2 New Maintenance Terminology

30

2.3 Maintenance Strategies over Time

34

2.4 Plant Maintenance over Time in SAP

37

2.5 SAP ERP 6.0

38

2.6 SAP GUI and SAP Business Client

43

2.6.1 Connection Options

43

2.6.2 General Functions

45

3 Organizational Structures

51

3.1 SAP Organizational Units

51

3.1.1 The Plant from a Maintenance Perspective

52

3.1.2 Maintenance-Specific Organizational Units

52

3.1.3 Other General Organizational Units

54

3.1.4 Plant-Specific and Cross-Plant Maintenance

55

3.2 Work Centers

57

4 Structuring of Technical Systems

65

4.1 Actions before Mapping Your Technical Systems in the SAP System

66

4.1.1 Question 1: Which Structuring Resources Should Be Used?

66

4.1.2 Question 2: How Deep Should the Structure Be?

68

4.1.3 Question 3: Which Criteria Should Be Applied to the Structuring of Technical Systems?

71

4.1.4 Question 4: On Which Structure Level Should a Particular Resource Be Used?

71

4.1.5 Question 5: How Are Numbers Assigned?

76

4.1.6 Question 6: Which Information Should You Store?

78

4.1.7 Question 7: How Is the Master Data Incorporated into the SAP System?

79

4.1.8 Question 8: Is It Easy to Delete Data Records?

79

4.1.9 Question 9: Which of the Functions Available Should Be Used?

80

4.1.10 Question 10: Which Strategy Should You Pursue When Recording Master Data?

80

4.2 SAP Resources for Structuring Technical Systems and How to Use Them

81

4.2.1 Functional Locations and Reference Functional Locations

81

4.2.2 Equipment and Serial Numbers

92

4.2.3 Links and Object Networks

103

4.2.4 Linear Asset Management

104

4.2.5 Material and PM Assemblies

112

4.2.6 Bills of Materials

119

4.2.7 Classification

123

4.2.8 Product Structure Browser

130

4.2.9 Asset Viewer

131

4.2.10 Special Functions

132

5 Business Processes

161

5.1 What You Should Do before You Map Your Business Processes in the SAP System

162

5.1.1 Question 1: Which Functions Should You Use?

162

5.1.2 Question 2: Should You Use a Notification and/or an Order?

163

5.1.3 Question 3: Which Information Should You Store?

167

5.1.4 Question 4: How Can You Ensure That Users Accept the System?

168

5.1.5 Question 5: What Role Does Business Process Modeling Play?

168

5.1.6 Question 6: When Should You Include the Other User Departments?

169

5.2 “Planned Repairs” Business Process

170

5.2.1 Notification

172

5.2.2 Planning

189

5.2.3 Controlling

221

5.2.4 Processing

235

5.2.5 Completion

237

5.3 “Immediate Repairs” Business Process

247

5.3.1 Creating Order (with Notification) and Completion

249

5.3.2 Special Case: “After-Event Recording“

252

5.3.3 Confirming Unscheduled Tasks

253

5.3.4 Historical Order

254

5.4 Shift Notes and Shift Reports

256

5.5 “External Assignment” Business Process

263

5.5.1 Basic Principles of External Assignment

263

5.5.2 External Processing as an Individual Purchase Order

266

5.5.3 External Services with External Work Centers

271

5.5.4 External Processing with Service Specifications

275

5.6 “Refurbishment” Business Process

280

5.7 “Subcontracting” Business Process

291

5.8 “Preventive Maintenance” Business Process

299

5.8.1 Basic Principles of Preventive Maintenance

299

5.8.2 Objects of Preventive Maintenance

302

5.8.3 Maintenance Task Lists

305

5.8.4 Preventive Maintenance, Time-Based

315

5.8.5 Preventive Maintenance, Performance-Based

336

5.8.6 Preventive Maintenance, Time-Based and Performance-Based

345

5.8.7 Inspection Rounds

353

5.9 “Condition-Based Maintenance” Business Process

360

5.10 “Calibration of Test Equipment” Business Process

364

5.11 “Follow-Up Order” Business Process

375

5.12 “Pool Asset Management” Business Process

377

5.13 “Project-Based Maintenance“ Business Process

385

5.13.1 SAP Project System

386

5.13.2 Maintenance Event Builder

392

6 Integrating Applications from Other Departments

397

6.1 How Other Departments Are Involved

397

6.2 Integration within SAP ERP

398

6.2.1 Materials Management

399

6.2.2 Production Planning and Control

408

6.2.3 Digression: In-house Production of Spare Parts for Stock

413

6.2.4 Quality Management

418

6.2.5 Environment, Health, and Safety

419

6.2.6 Financial Accounting

421

6.2.7 Asset Accounting

423

6.2.8 Controlling

427

6.2.9 Real Estate Management

437

6.2.10 Human Capital Management

440

6.2.11 Service and Sales

445

6.3 Integration with Other SAP Systems

448

6.3.1 SAP NetWeaver Master Data Management

448

6.3.2 SAP Master Data Governance

450

6.3.3 SAP Supplier Relationship Management

454

6.4 Integration with Non-SAP Systems

457

6.4.1 Operations Monitoring Systems

457

6.4.2 Operations Information Systems

460

6.4.3 Service Specifications and Entry of Services Performed

463

7 Plant Maintenance Controlling

467

7.1 What Plant Maintenance Controlling Involves

467

7.2 SAP Tools for Obtaining Information and How to Use Them

471

7.2.1 SAP List Viewer

472

7.2.2 QuickViewer

480

7.2.3 SAP ERP Logistics Information System

485

7.2.4 SAP Business Warehouse

494

7.2.5 SAP BusinessObjects Lumira

506

7.3 SAP Tools for Budgeting and How to Use Them

512

7.3.1 Order Budgeting

512

7.3.2 Cost Center Budgeting

514

7.3.3 Budgeting with IM Programs

515

7.3.4 Budgeting Using WBS Elements

518

7.3.5 Maintenance Cost Budgeting

522

8 New Information Technologies in Plant Maintenance

531

8.1 Electronic Parts Catalogs

532

8.2 New Technologies in the User Interface

534

8.2.1 SAP 3D Visual Enterprise Viewer

534

8.2.2 SAP Fiori

537

8.2.3 Quick Views

540

8.3 Mobile Maintenance

542

8.3.1 Fundamentals of Mobile Maintenance

542

8.3.2 Paging

548

8.3.3 SAP Work Manager

550

8.3.4 SAP Rounds Manager

559

8.3.5 SAP Fiori Apps for Plant Maintenance

560

8.3.6 RFID

566

8.4 SAP HANA

569

8.4.1 Introduction to SAP HANA

569

8.4.2 SAP HANA and Maintenance

573

8.5 SAP S/4HANA

575

8.6 SAP Predictive Maintenance and Service

578

8.7 SAP Asset Intelligence Network

581

9 Usability

591

9.1 What Is Meant by Usability?

592

9.2 Assessing Usability

597

9.3 Why Usability Does Not Mean User Acceptance

598

9.4 The Importance of User Acceptance in Plant Maintenance

601

9.5 SAP System Options to Improve Usability

604

9.5.1 General User Parameters

605

9.5.2 Maintenance-Specific User Parameters

606

9.5.3 Roles and Favorites

608

9.5.4 List Variants

610

9.5.5 Customizing Input Help

610

9.5.6 Buttons and Key Combinations

611

9.5.7 Table Controls

612

9.5.8 Transaction Variants

615

9.5.9 Customizing

617

9.5.10 Action Box

618

9.5.11 GuiXT

620

9.5.12 SAP Screen Personas

621

9.5.13 Upstream Transactions

625

9.5.14 Web Interface

628

9.5.15 Customer Exits

629

9.5.16 Other Programming Techniques

631

9.6 Usability Study for SAP ERP 6.0

634

9.6.1 Preparation and Execution

634

9.6.2 Results

639

9.6.3 Conclusions

644

Appendices

647

A List of Sources

649

B Overviews

655

B.1 Functional Comparison of Structuring Resources

655

B.2 Functions of Notifications and Orders

656

B.3 Integration Aspects

661

B.4 Standard PM-IS Reports

668

C The Author

671

D Acknowledgments

673

Index

675