Hi all,

I am working in preventive maintenance part for a beer company. I want to know which plant maintenance methods (RCM,TPM,etc)is the best option to implement in SAP?

Thanks

I think Preventive Maintenance is the easiest method to implement in SAP R/3, and probably at each major CMMS in the market. Just:
* have your PM workscopes (instructions) defined,
* define specific frequency intervals for each instruction;
* enter the instructions (operations /suboperations) at the system,
* assign frecuency,
* set up maintenance plans - linking the instructions to the equipments and you are basically up and running.

TPM? Is there any scheduling difference between Preventive Maintenance and Total Productive Maintenance?

RCM? How to tell SAP R/3 when the next order for the equipment 100MTR001 shall be generated/created?

I think we can implement results of either rcm or tpm in sap pm. This is becasue both rcm and prev maint pillar of tpm are each used to develop the plant maint program which can be implemented in the plant via sap pm. From budget point of view, it's not likely you will do both, provided done properly.

I would think standard rcm is quite a technically-rigorous method that will give a technical basis for your maint program compared to inhouse works which could be based on generic maint strategies and improved following local experience in the plant, OEM checklists which could be excessive in nature in not checked by users etc.

What I read from tpm, I have not seen a structured method to come up with the maint program specified such as rcm.

Whatever it is, I'm sure sap pm can accommodate both conditioned-based and time-based maint program.

One of the benefits I expect from a CMMS is to provide the Maintenance Engineering organization with the "memory tickle" of its is time to return to the equipment 123XYZ001 and perform the required maintenance.

With time based PM it is easy to configure, and I would say any CMMS. Speaking in SAP R/3 terms is only to:
* create the equipments.
* create the tasks lists with the instructions to be carried out, which parts get from the stockroom, which craft(s) are responsible, at which frecuency each instruction must be repeated.
* create Maintenance plan that tie the above two togheter
* create a maintenance strategy that rule how and when the system will generate the maintenance orders.

Since the tickle is time based, the internal system clock will alert SAP R/3 to alert us, by the generation of the PM orders, that the time has come.

But the question is, how to tell SAP R/3 "condition-based" (not time based) that the time to return to the equipment has come?

Or the answer is to run a PM on a monthly basis (or defined time interval) to:
* inspect X condition at the equipment,
* record readings at the order,
* and if the reading is within this particular range then issue another order with the RCM task list number 12345?
(Time-based PM orders used to inspect/ monitor/ record conditions to issue RCM orders condition-based?)

To to avoid waiting for a second order, include the RCM tasks as suboperations of the PM inspection operation; then the RCM suboperations are executed only if the results of the inspection indicates so (condition-based)?

This message has been edited. Last edited by: Eugene,

To accommodate condition-based maint in SAP PM, create measurement points for the equipment. Can specify min/max limits for these points. Also can generate meter-based PM.

Josh:
The readings to be recorded during the PM orders would be recorded at SAP R/3 using the measurement points, with the range expressed as min/max limits.

But how to generate the meter based orders without time based orders?

How do you tie SAP R/3 to X metering device reading Y condition on equipment 123XYZ001, so SAP would "know" that the condition Y has reached the max or min limit and a new order must be generated to perform the maintenance task list 12345?

Could you ilustrate an example using pump alignment, motor bearing vibration, or something else?

This message has been edited. Last edited by: Eugene,

Eugene,

quote:

To to avoid waiting for a second order, include the RCM tasks as suboperations of the PM inspection operation; then the RCM suboperations are executed only if the results of the inspection indicates so (condition-based)?

Unless the corrective action is very simple waiting for a planned response is best. The inspection method, frequency and alert levels should be selected to ensure that there is sufficient warning of failure to be able to plan and schedule a corrective action.
At my workplace, a major hazard facility manufacturing Polyethylene, there is also the safety aspect to consider. A work permit detailing all the required precautions would be issued for the inspection tasks, any follow-up item would need a new permit to work issued which acknowledges any new precautions required to be taken.

Safety first. Yes a second work permit will be required if the first one did not considered the impact of the additional instructions included at the order.

When generating the first permit the issuer and the aceptor must answer this question:
For which order is this permit?
* an order to inspect and document equipment conditions, or
* an order to inspect, document, and fix if applicable the equipment conditions?
Then, the list of required precautions can be defined.

A typical instruction in our PM is:
0100 Verify pressure at gauge A1, document reading: ________ PSI. Change the filter #1 if reading is over XX PSI.
The work permit must include required precautions for the filter change activity, not only for the PPE required to enter a mechanical room or to an exterior utilities area to read gauges and copy readings to the orders at the clipboard.

This message has been edited. Last edited by: Eugene,