SAP PM Practice

Implement PM

In the majority of the industrial companies, the Plant Maintenance area is very important in terms of annual budget, impact in the production process and complexity of the resources administration.

 

The maintenance systems are a key tool that help determine whether the investments made in equipment maintenance result in an increase in the availability and productivity of these assets, optimizing at the same time the resources (both capital as well as human) allocated to achieve these objectives. They also are an excellent platform to better organize and expedite the day to day operations.

 

In order to achieve a successful implementation of a maintenance system, it is essential that the assigned team understands the particular characteristics that this type of projects have.

 

  • Timing/Resources: Even though the number of consultants required for SAP PM projects is less than the required for other modules (MM, FICO, etc), the number of users and the fact that the plants are typically scattered, makes the duration of the project longer.

  • Historic Facts: The SAP PM long term benefits are focused in the gathering and analysis of the information of the maintenance daily operation. This data base is important for the maintenance management because it offers a source of information that supports decisions such as: reassigning tasks/professionals, identifying malfunctioning equipment or changing the frequency of the preventive maintenance activities.

  • Master Data: A solid data base with the proper definition of the technical structures and organizational units, is needed so that the historic data of the maintenance system is consistent and properly organized.

  • Change Management: The plant maintenance activities involve a great number of operators, which once the system is implemented, become users of the PM module.  The information flow and end-user training become key factors in order to get the people involved and understand the benefits of the new system.

Diagnosis

The experience of Iquant’s professionals in business processes and maintenance systems allows delivering a diagnosis service of the operation and use of these systems.

 

Our diagnosis method consists in evaluating a list of relevant aspects in order to determine the evolution state of the organization and the analyzed system.

 

We have specified the following evolution levels:

 

 

 

 

 

 

 

 

 

 

The detail of each level can be found in the White Paper Iquant’s point of view

 

Iquant guides its customers through this evolution cycle, proposing changes and improvements that will take the system to the next level. Iquant has a vast EAM practice that allows them to understand the integration between business processes and the information systems. Iquant understands the problems of this integration and which is its true potential. We have listed below the areas in which we can work through the maturity cycle in order to achieve the maximum potential of the maintenance system.

 

The result of a complete diagnosis will identify the evolution level, the main improvement opportunities and will suggest an action plan designed to achieve the next level.

 

Iquant has pre-determined the following diagnostic services:

 

Master data and organization quality diagnosis

 

The creation of a failure and repair data base is one of the principal benefits of a SAP EAM (PM) implementation. A solid master data base is very important to achieve the proper organization of the registered data, providing users with information that will be useful to make management decisions.

 

A survey of the active master data in the system is made, analyzing the following aspects:

 

  • Connection between the data volume and the magnitude of the facilities organization.

  • Consistence in the relation between objects.

  • Procedure  for the master data administration.

  • Data quality and precision.

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The result will be delivered in a written report stating the detected quality and the necessary corrections.

 

Diagnosis of integration between the business processes and SAP-PM


The main maintenance processes integrated With SAP-PM are examined, analyzing the following aspects:

 

  • Definition of document types and its applications.

  • Definition of roles and system responsibilities.

  • Integration with the Materials Management module.

  • Integration with the Controlling module.

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The result will be delivered in a written report stating the improvement opportunities and the suggested steps to be followed.

 

Diagnosis of SAP-PM utilization level 

A study of the transactional data is carried out, evaluating the following key aspects:

 

  • Analysis of the volume of documents generated for each Plant Maintenance activity type, categorized by areas.

  • Quality of the documents and their value as historic data.

  • Reliability of the available reports for making decisions based on the collected information.

  • Execution of the business processes and procedures as defined during the system   implementation.

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The result will be delivered in a written report describing de current state of the system utilization.

 

Complete Diagnosis 
This includes the analysis of the quality of the master data, the SAP-PM integration with the maintenance business processes and the level of utilization of the system. The result of this diagnosis will determine the evolution level of the system, stating the current situation and the steps to be taken to achieve the next level.

 

Problem resolution Analysis
This service helps the IT department analyze, classify and purify the list of issues detected after the implementation of the system, with the objective of identifying the critical condition and order in which the issues should be solved. The result will be a detailed and prioritized list, identifying the cause of each issue (system error, incorrect definition of processes, lack of training, etc.) and the possible resolution alternatives. 

Note: The duration of all the diagnostic services may vary according to the size and complexity of the analyzed firm.

Methodology

The methodology used in EAM related projects, must be tailored to match the particular characteristics of the PM Module implementation.
The methods Iquant uses for the EAM practice, allow its consulting professionals to achieve a better use of time in each of the project stages.

 

Iquant has developed specific and standardized tools for EAM projects which help achieve the targeted results in the planned time.

 

Analysis and Design

 

  • Standard questions which are used to lead the information gathering

  • Business process matrix including relevant attributes and variants

  • Recommendations on main definitions and examples of solutions which have been adopted in other cases from the industry

  • General outline of the “best practices” for the main processes in each industry

  • Pre-designed configuration guide classified by process, integration with other modules, the person responsible for the definition and a recommendation of changing or leaving the default configuration

  • Knowledge of the typical developments made on PM module.

 

Construction

 

  • Complete fields map and structures of PM Module

  • Template of functional designs with the relevant information for the development team

  • Model matrix of security profiles (simple vs complex definitions)

  • Inventory of security objects usually used for security validations on PM Module.

 

Final Preparation

 

  • Standard and easy to use charts for the preparation of master data

  • Pre-manufactured tools for the validation and mass creation of data (MS Access to validate and generate IBIP records, predesigned LSMW)

  • Prototpesy of training manuals for final users.

 

Go Live

 

  • List of common issues and the proposed solution

  • Know-how of how to deal with maintenance users.

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