01.preventive Maintenance Routine_24.09.2012

Create Notification Preventive Maintenance Routine Cilacap Plant, Maintenance Department Planning Section

September 2012

Agenda

Memahami konsep Maintenance strategy

Mengetahui bagaimana membuat Task List

Mengetahui bagaimana membuat Maintenance Plans/ Items untuk time-based and counter-based maintenance

Mengetahui bagaimana menjalankan automatic Scheduling and Deadline Monitoring

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Maintenance Planning

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Agenda  Planned Maintenance Process Overview  Maintenance Strategy

 Maintenance Task List  Maintenance Plan & Maintenance Item  

Scheduling Deadline Monitoring and Work Order generation

 Exercises

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Maintenance Planning

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Planned Maintenance Overview  Maintenance Strategy merupakan pengaturan frekuensi

(pakages) yang digunakan dalam pembuatan task list dan maintenance plan  Task list di dalamnya berupa aktivitas pekerjaan, langkah

pekerjaan, manhours yang dibutuhkan, dan masing-masing didefinisikan sebuah packages.  Maintenance plan dibuat untuk task list, di mana untuk

mendefinisikan pegaturan schedule untuk beberapa aktivitas di dalamnya.  Di dalam maintenance plan ada maintenance item untuk

menentukan technical object, order type, prioritas dll..  Maintenance Plan yang terschedule untuk calling work order.  Sedangkan deadline monitoring untuk pengaturan otomatis

calling work order. 4

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Flow Process PMR Maintenance Strategy

Maintenance 1

Task List

Task List

Task List

Planners Bertanggung

Maintenance Item

Maintenance Item

Maintenance Item

Untuk building

2 Maintenance Plan

Planned maintenance di SAP dapat berupa periode basis (daily, weekly, monthly, etc.) atau performance basis (hours, miles, kilometers, tons, etc.)

jawab

3

Schedule Maintenance Plan

4

Deadline Monitoring (background processing)

PMR.

PM02 Orders PM02 Orders Auto-created & Released Preventive Orders 5

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Preventive Maintenance Object and Work Order

Work order Header

Maintenance Item

Scheduled date

Maintenance Plan

Operation Resources

Work Order

Strategy Task List

Preventive Maintenance module

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Agenda  Planned Maintenance Process Overview  Maintenance Strategy

 Maintenance Task List  Maintenance Plan & Maintenance Item  

Scheduling Deadline Monitoring and Work Order generation

 Exercises

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Maintenance Strategy IP11: Overview  Maintenance Strategy ini untuk dilinkkan ke task list dan

maintenace plan.  Di dalamnya merupakan packages sebagai counter milestones.  Dapat diset menurut

waktu (time based)  equipment performance (Counter-based, e.g. Operating Hour, Product volume, mileage).  Maintenace strategy dapat digunakan untuk beberapa maintenance plan 

 Dibedakan menjadi 2 type:  

Dengan Hierarchy Tanpa hierarchy

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Maintenance Strategy IP11 (2) Klik

(1)Double Klik (3) Back

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Maintenance Strategy IP11

(1) Double Klik

(2) Change Cycle

(3) Klik untuk melihat maintenance Plan yang menggunakan strategy SCTIME PT Holcim Indonesia Tbk

Maintenance Planning

(4) BACK (5) SAVE 10 28.01.2020/CC_PLANT/MTC

The Maintenance Strategy dengan Hierarchy Dengan hierarchy : jika 1 task list mempunyai lebih dari 1 operation dengan package yang berbeda, maka ketika dicalling, hanya operation dengan package terbaru yang muncul

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Standard strategy dengan hierarchy

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Standard strategy tanpa hierarchy Tanpa hierarchy : jika 1 task list mempunyai lebih dari 1 operation dengan package yang berbeda, maka ketika dicalling, semua operation akan muncul.

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Standard strategy tanpa hierarchy

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Types of Planned Maintenance Planned Maintenance

Time-based

Performance-Based

Based on Condition

Temperature 1 Week 3 months 6 months 1 year

Pressure Run Hrs (500 hrs) Prod Vol.

Thickness

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The Maintenance Strategy: Time Based

1 Month Virtual inspection External

3 Months Virtual inspection Internal

Which parts need to be inspected at what intervals ?

1 Year Check gear teeth for abrasion

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Example : Time Based Plans

168d 24w 12w 4w 1w

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 21 22 23 24

Weekly Maintenance Cycle 17

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Maintenance Strategy – Time Based

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Maintenance Planning

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Maintenance Strategy – Counter-Based

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Agenda  Planned Maintenance Process Overview

 Maintenance Strategy  Maintenance Task List  Maintenance Plan & Maintenance Item  

Scheduling Deadline Monitoring and Work Order generation

 Exercises

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Maintain task List –All Types  Mendefinisikan urutan maintenace task untuk work

scheduling.  System akan secara otomatis memunculkan nomor urut

berupa group counter untuk setiap task list.  General task list tidak mengacu pada specific technical object.  General task list dapat digunakan untuk semua technical

object yang sesuai.  Types dari Task lists - General Task Lists - Functional Location Task Lists - Equipment Task Lists 21

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Task List and Maintenance Strategy

Time / Run hours Task List Operation 10 Operation 20 Operation 30 Operation 40 Operation 50 500 Hrs

Operation 60 Operation 70

1000 Hrs 22

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Rekomendasi Task list Condition Monitoring Techniques Greasing route Lubrication

Oil and grease replacement Oil Sampling & Analysis Walk By inspection Vibration route Thermography EMD

Condition Monitoring

NDT

Example All routes with greasing and quantity of grease Fixed time replacement of oil for small GB - No oil analysis performed Sampling analysis of oil of main equipment Maintenance walk by inspection All routes used for Vibration analysis with data collector Routes for thermography analysis Either static of Dynamic measurements VT, PT, MT, UT, E Current

Level for Work Order

Task List

Code

Area/Line

General Task List

LUB

Equipment

General Task List

OIL

Area/Line

General Task List

OIL

Area/Line

General Task List

WBI

Area/Line

General Task List

VIB

Area/Line

General Task List

THM

General Task List

EMD

General or Functional Location Task List

NDT

Functional location Level 5 / Equipment Functional location Level 5

Equipment specifc measurement

Shell test, lead wire, Run Functional location out etc Level 5

General or Functional Location Task List

Equipment HAC in 2 digits

Downtime Inspection

Visual inspection, calibration, cleaning, Functional location replacement, adjustment Level 5 / Equipment or services

General or Functional Location Task List

Equipment HAC in 2 digits

Wear mesurement

Liners, thickness, elegation, hardness…

General or Functional Location Task List

Equipment HAC in 2 digits

Functional location / Equipment

Avoid usage of equipment task list 23

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Penamaan Task List • Selalu diawali dengan kode Plant:  

Work Center (3 digit) Task (Vibration/VIB)

CC CCPM2 CCPM2VIB

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Create Task List T-Code : IA05

Enter

Masukan Nama Task List

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Header Task List (7) Klik Operation

T-Code : IA05 (1) Deskripsi diawali dengan Packages (1W/1M/PMS/dll)

(3) 4 : Plant Maintenance

(2) Work Center & Plant

(4) 4 : Released (General)

(6) Masukan Maintenance Strategy

(5)

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Operation Task List Purchase request untuk service dapat dibuat menggunakan ControlKey PM02 or PM03 seperti di work order (1) Masukan operation Description

(3) Double Klik pada LT(Long Text) untuk menambahkan standard kerja

(2) Isikan data duration dan jumlah karyawan

(5) Klik Components untuk memasukan material

(4) Klik MntPack 27

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Long text (1) Back

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Maintenance Packages (2) Klik Task List

(3) Back

(1) Pilih Packages

Klik Delete untuk menghapus group counter Klik New Entries untuk menambahkan group counter 29

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Create Notification Standard Text Cilacap Plant, Maintenance Department

Create Standard Text 1.SAP Menu Logistics Plant Maintenance Work Scheduling Extras – CA10 (Standard Text) ATAU T-Code CA10

Preventive Maintenance

2.Lalu Tekan atau ENTER keyboard

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Create Standard Text 1. Lalu Tekan Create

3. Save 2. Isikan Standard Text

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Attach Standard Text to Operation Task List 3. Save

1. Isikan Standard Text 2. Enter

Yes : Long Text akan diganti standard text secara keseluruhan No: menambahkan Long Text dengan standard text

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Task List Change General Task List

Display General Task List

T-Code : IA06

T-Code : IA07

Change PM Task List

T-Code : IA09

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Agenda  Planned Maintenance Process Overview  Maintenance Strategy

 Maintenance Task List  Maintenance Plan & Maintenance Item  

Scheduling Deadline Monitoring and Work Order generation

 Exercises

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Maintenance Item Maintenance Plan

1 Maintenance Item = 1 Work Order

Maintenance Schedule

Maintenance Item

Objects Funct. locations Equipments

Task lists

W h a t w o r k h a s t o b e d o n e ?

W h o i s t o d o t h e w o r k ? 36

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Rekomendasi Penamaan Maintenance Item

Maintenance Item

Freq+Time+Condition+Task+Area

1MMO1RUNVIBRM

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Create Maintenance Item 1. SAP Menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Maintenance Plans Maintenance Item  IP04 - Create ATAU T-Code IP04 Lalu tekan Atau ENTER keyboard 2.

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Create Maintenance Item (4) Enter (1) Masukan Nama Maintenance Item

(2) Pilih Standard maintenance plan (3) SCTIME

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Create Maintenance Item

(1) Deskripsi Maintenance Item

2 1

(2) Isi Functional Location & Equipment

3

(3) Planning Plant : I400 Order type : PM02 (4) Isikan Main Work center & I400

(5) Isikan Planner Group & maintActivity Type

(6) Type : A (General Task List) (7) Masukan Task List Group & Group Counter

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(8) ENTER

Maintenance Planning

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Create Maintenance Item

(2) SAVE

(1) Pilih Priority

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Create Maintenance Item

(4) SAVE (1)Klik

(2) Masukan Nomor Equipment

(3) ENTER

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Maintenance plans didefinisikan sebagai proses scheduling sehingg dapat untuk call work order

 Maintenance plan di dalamnya terdapat element

preventive maintenance.  



Strategy dengan packages Maintenance Item Task List

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Maintenance Planning

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Create Maintenance Plans (Strategy Plan) 1. SAP Menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Maintenance Plans Maintenance Plans  IP42 – Strategy Plan ATAU T-Code IP42 Lalu tekan Atau ENTER keyboard 2.

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Create Maintenance Plans (Strategy Plan) (4) Enter

(1) Masukan Nama Maintenance Plan

(2) Pilih Standard maintenance plan (3) SCTIME

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Create Maintenance Plans (Strategy Plan)

(1)Klik Assign more item

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Create Maintenance Plans (Strategy Plan) (6) Excute

(1) Masukan Maintenance Item (1) Atau klik Multiple selection jika ingin memasukan maintenance item lebih dari satu

(4) Excute

(5) Choose (3) Copy

(2) Copy maibtenance item dari excel kemudian klik upload from clipboard

(7) Isikan deskripsi Maintenance Plan

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Maintenance Planning

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Create Maintenance Plans (Strategy Plan) (1) Klik Item overview

(1) Klik Cancel Item Assignment untuk mendelete maintenance item

(1)Klik Assign more item untuk menambahkam maintenance item PT Holcim Indonesia Tbk

Maintenance Planning

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Create Maintenance Plans (Strategy Plan) (2) SAVE

(1) Klik

(3) Continue

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T-Code : IP02

T-Code : IP03

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Maintenance Scheduling Parameter: Recommendation 1/3

Time : Settingan default Time Key date: Plan Date akan muncul pada tanggal yang sama Jangan digunakan untuk tanggal yang lebih dari tanggal 28

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Maintenance Scheduling Parameter: Recommendation 2/3

Jangan di centang agar menghindari tidak sesuainya scheduling

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Maintenance Scheduling Parameter: Recommendation 3/3

Call Horizon: default 80% Scheduling Period: 91 days untuk default Jika Packages >3M maka gunakan 1 YR

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Rekomendasi Naming Maintenance Plan

• Start dengan Plant Code   



Line Trades (M, E, Lub, PM etc) Type of maintenance (WBI, NDT) Increment number

CC CC2 AE5-M AE5-M-WBI AE5-M-WBI01

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Agenda  Planned Maintenance Process Overview  Maintenance Strategy

 Maintenance Task List  Maintenance Plan & Maintenance Item  

Scheduling Deadline Monitoring and Work Order generation

 Exercises

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Agar dapat memunculkan order maka Maintenance Plan perlu scheduling

Maintenance Plan

No Work Order Generated

Scheduled Maintenance plan

No Work Order Generated

Run Deadline Monitoring Run standard deadline monitoring in background Maintenance Call = Work Order 56

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Schedule Maintenance Plan 1. SAP Menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Scheduling for Maintenance PlansIP10 – Schedule ATAU T-Code IP10 Lalu tekan Atau ENTER keyboard 2.

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Schedule Maintenance Plan (2) Enter

(1) Masukan Nama Maintenance Plan

(3) Start

(3) Isikan tanggal (4)Continue

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Schedule Maintenance Plan (1) SAVE

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Maintenance Planning

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Schedule a Maintenance plan – IP10: Screen explanation

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Restarting a Plan

1. Klik Restart

2. Klik Delete 3. Masukan tanggal start of cycle 4. Continue (Enter) PT Holcim Indonesia Tbk

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Deadline Monitoring – IP 30 1. SAP Menu  Logistics  Plant Maintenance  Preventive Maintenance  Maintenance Planning  Scheduling for Maintenance PlansIP10 – Deadline Monitoring ATAU T-Code IP30 Lalu tekan Atau ENTER keyboard 2.

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Deadline Monitoring – IP 30 (4) Excute

(1) Masukan Maintenance Plan

(2) Masukan Maintenance Strategy ; SCTIME (3) Masukan Interval calling (5) Back

(6) Continue (Enter)

(8) Back

(7) Back

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Schedule Maintenance Plan – IP10 Before

After

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Steps to create a maintenance plan  Create a Task List

IA05

Maintenance Item

 Create Maintenance Item

IP04

Maintenance Plan

 Create Maintenance Plan

IP42

 Schedule Maintenance Plan

IP10

 Deadline Monitoring

IP30

Task List

Deadline Monitoring

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Maintenance Master Schedule (13 week) Cilacap Plant, Maintenance Department Planning Section

September 2012

Maintenance department

Maintenance Master Schedule • Deskripsi 

Perencanaan selama 3 bulan semua aktivitas maintenance dan resources yang mempertimbangkan : - Labor Availability - Planned / Predictive Maintenance Routines - Task Priorities - Material and Spare Parts Availability

• Tujuan Untuk mengidentifikasi kebutuhan maintenance resource dan mengoptimalkan maintenancve optimize • Contoh 



Quarterly Master Schedule, on weekly basis

67 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Maintenance Master Schedule Overview Frequency

Crew & Duration

Maintenance Routines

Maintenance Standards

Packing & Dispatch Finish Mill Raw Mill Quarry Kiln

Labor Availability

Productivity / Reactive Allowance

Labor Schedule

Contractor Process Mechanical Electrical

Master Schedule Summary

Tradesmen Summary

Quarterly on weekly basis Maintenance Schedule Output

Output

Output

 Preventive Maintenance Routines  Planned Corrective Jobs  Capital Improvement Projects

 Earned Standard Labor Hours (E.S.L.H.) by process area.  Actual Labor Hours inclusive of breakdown & productivity factor.

      

Re-schedule jobs. Cancel Jobs. Re-allocate jobs. Increase / Reduce Overtime. Adjust Holiday / Training plans. Increase / Reduce Crewing. Modify Shift Patterns. 68

Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Daily / Weekly Plan LEVELS OF MAINTENANCE PLANNING

Maintenance Master Schedule

Weekly Plan

Daily Plan

 Capacity and Resource Planning  Medium Term (quarterly, on weekly basis)  ‘What-If’ Modeling

 Weekly Scheduling  Task Prioritization (maintenance/production)  Planning of skills, resource and equipment requirements  Allocation of tasks to individuals  Flexing of the plan on a daily basis 69

Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Capacity Planning – CM01 1.

SAP Menu  Logistics  Plant Maintenance  Maintenance Processing Capacity Requirement Planning  Evaluation  Work Center View CM01-Load

ATAU T-Code CM01

2.

Lalu tekan

Atau ENTER keyboard

70 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Capacity Planning – CM01

(1) Work center (3) Klik (2) Plant :

I400

13 Weeks Planning

71 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Capacity Planning – CM01

72 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Capacity Planning – CM01 4 Weeks Planning

Double Klik

73 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Change Work Center (Change Available Capacity) – IR02

1.

SAP Menu  Logistics  Plant Maintenance  Management of Technical Objec  Environment Work Centers  IR02 – Change ATAU T-Code IR02

2.

Lalu tekan

Atau ENTER keyboard

74 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Change Work Center (Change Available Capacity) – IR02

1. 2.

Plant : I400

Work Center

(3) Klik

1 2

(4) Klik 75 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Change Work Center (Change Available Capacity) – IR02 (1)

Klik Intervals

Capacity

(2)

Klik Insert

(3) Mulai Tanggal Valid sampai selesai

(4) Ganti Individual Capacity

(5) Enter

(6) Enter

76 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Change Work Center (Change Available Capacity) – IR02 SAVE

Before

After

77 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

Recommendation • Maintenance request should be created in SAP for better scheduling and balancing work load • Refresh training to end users to ensure properly Notification created • Timely convert all Notifications to work order and scheduling in 13 weeks basic

• Develop PMR 



Develop PMR with support from PM team leader, Utility, Electricals and Hydraulic lubrication team Develop PMR for Quarry

78 Maintenance Department

Maintenance Master Schedule (Optional) File source, Department or division, Creator

79 Maintenance Department (Optional) File source, Department or division, Creator