About This Book

19

Target Audience

20

What This Book Can and Cannot Do

21

Structure of This Book

22

What’s New to This Book?

24

Acknowledgments

24

1 Introduction to Plant Maintenance with SAP S/4HANA

27

1.1 Plant Maintenance Today: New Ideas Need New Space

28

1.2 New Plant Maintenance Terminology

29

1.3 Maintenance Strategies Over Time

33

1.4 SAP S/4HANA Application System

34

1.4.1 Deployment Models

34

1.4.2 SAP S/4HANA Overview

36

1.4.3 Enhancement Packages and Business Functions

37

1.5 SAP Best Practices

40

1.6 SAP HANA Database

41

1.7 User Interfaces

42

1.7.1 SAP GUI

42

1.7.2 SAP Fiori

44

1.8 Summary

47

2 Organizational Structures

49

2.1 SAP Organizational Units

49

2.1.1 The Plant from a Maintenance Perspective

49

2.1.2 Maintenance-Specific Organizational Units

50

2.1.3 Other General Organizational Units

51

2.1.4 Plant-Specific and Cross-Plant Maintenance

52

2.2 Work Centers

53

2.3 Summary

61

3 Structuring of Technical Systems

63

3.1 Actions to Take Before Mapping Your Technical Systems in SAP

63

3.1.1 Question 1: Which Structuring Resources Should Be Used?

64

3.1.2 Question 2: How Deep Should the Structure Be?

66

3.1.3 Question 3: Which Criteria Should Be Applied to the Technical System Structure?

68

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

68

3.1.5 Question 5: How Are Numbers Assigned?

71

3.1.6 Question 6: Which Information Should You Store?

73

3.1.7 Question 7: How Is Master Data Incorporated Into the SAP System?

74

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

74

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

75

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

75

3.2 Functional Locations and Reference Functional Locations

76

3.2.1 Creating Functional Locations: Single Entry

77

3.2.2 Creating Functional Locations: Collective Entry

82

3.2.3 Reference Functional Locations

83

3.2.4 Alternative Labeling

83

3.3 Equipment and Serial Numbers

86

3.3.1 Installing Equipment on Functional Locations/Dismantling Equipment from Functional Locations

89

3.3.2 Placing Equipment in Storage/Removing Equipment from Storage

90

3.3.3 Equipment Hierarchies

94

3.3.4 Functional Comparison Between Pieces of Equipment and Functional Locations

95

3.4 Links and Object Networks

96

3.5 Linear Asset Management

98

3.6 Material and Plant Maintenance Assemblies

104

3.7 Bills of Materials

109

3.8 Classification

113

3.9 Product Structure Browser

119

3.10 Asset Viewer

120

3.11 Generic Functions

121

3.11.1 Data Transfers

121

3.11.2 Mass Change of Equipment and Functional Locations

123

3.11.3 Measuring Points and Counters

125

3.11.4 Documents

130

3.11.5 Address Management

133

3.11.6 Warranties

135

3.11.7 Partners

137

3.11.8 Permits

139

3.11.9 System Status and User Status

140

3.12 SAP 3D Visual Enterprise Viewer

143

3.13 SAP Geographical Enablement Framework

145

3.14 Summary

147

4 Work Order Cycle

151

4.1 Actions to Take Before Mapping the Work Order Cycle in SAP S/4HANA

151

4.1.1 Question 1: Which Functions Should Be Used?

152

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

152

4.1.3 Question 3: What Information Should Be Maintained?

155

4.1.4 Question 4: How Can You Ensure User Acceptance of the System?

156

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

156

4.1.6 Question 6: When Should Other Departments Be Involved?

156

4.2 Work Order Cycle Steps

157

4.3 Notification

159

4.3.1 Creating a Notification

159

4.3.2 Notification Content

166

4.3.3 Flexible Reference Objects

166

4.3.4 Object Information

167

4.3.5 Notification Items

168

4.3.6 Catalogs and Catalog Profiles

168

4.3.7 Detection Method

172

4.3.8 Priority Assessment

173

4.3.9 Classification

174

4.3.10 Partners

175

4.3.11 Addresses

176

4.3.12 Documents

177

4.3.13 Printing

178

4.3.14 System and User Statuses

179

4.3.15 Mass Change of Notifications

180

4.4 Plan Order

182

4.4.1 Creating an Order

183

4.4.2 Order Types

187

4.4.3 Content of Orders

188

4.4.4 Order Operations

188

4.4.5 Responsibilities

190

4.4.6 Scheduling

191

4.4.7 Material Planning

196

4.4.8 Electronic Parts Catalogs

202

4.4.9 Production Resources/Tools

204

4.4.10 Documents

205

4.4.11 Object List

206

4.4.12 Costing and Estimated Costs

207

4.4.13 Permits

211

4.4.14 Order Hierarchy

212

4.4.15 Object Services

213

4.4.16 Do Not Execute Orders

214

4.4.17 Printing Orders Before Release

216

4.4.18 Maintenance Planning Overview

216

4.5 Schedule Order

217

4.5.1 Mass Change of Orders and Operations

217

4.5.2 Capacity Requirements Planning

220

4.5.3 Availability Checks

224

4.5.4 Order Release

228

4.5.5 Shop Paper Printing

229

4.5.6 Paging

232

4.6 Execute Order

234

4.7 Confirm Order

235

4.7.1 Completion Confirmations

236

4.7.2 Technical Completion Confirmations

240

4.8 Complete Order

241

4.8.1 Technical Completion

241

4.8.2 Order Printing after Technical Completion

242

4.8.3 Business Completion

243

4.8.4 Document Flow

243

4.8.5 Action Log

244

4.9 Summary

245

5 Preventive Maintenance

247

5.1 Basic Principles of Preventive Maintenance

247

5.2 Preventive Maintenance Objects

250

5.3 Maintenance Task Lists

253

5.3.1 Task List Types

253

5.3.2 Maintenance Order and Task List

257

5.3.3 Action Log

260

5.3.4 Task List Costing

261

5.3.5 Mass Changes

261

5.4 Time-Based Maintenance Plans

263

5.4.1 Time-Based Single-Cycle Plan

263

5.4.2 Time-Based Strategy Plan

279

5.5 Performance-Based Maintenance Plans

286

5.5.1 Performance-Based Single-Cycle Plan

286

5.5.2 Performance-Based Strategy Plan

292

5.6 Multiple-Counter Plans

295

5.6.1 Basic Multiple-Counter Plan

296

5.6.2 Enhanced Multiple-Counter Plan

299

5.7 Inspection Rounds

302

5.7.1 Basic Inspection Rounds Using the Object List

303

5.7.2 Enhanced Inspection Rounds Using the Maintenance Task List

305

5.8 Condition-Based Maintenance

310

5.9 Summary

313

6 Other Business Processes

315

6.1 Immediate Repairs

315

6.1.1 Creating Orders and Completion

317

6.1.2 Report and Repair Malfunctions

319

6.1.3 After-Event Recording

321

6.2 Shift Notes and Shift Reports

325

6.2.1 Shift Notes

325

6.2.2 Shift Reports

328

6.3 External Assignment

330

6.3.1 Basic Principles of External Assignment

330

6.3.2 External Processing with Single Purchase Order

332

6.3.3 External Services with External Work Centers

338

6.3.4 External Processing with Service Specifications

342

6.3.5 External Services with Lean Services

346

6.4 Refurbishment

348

6.4.1 Prerequisites

350

6.4.2 Refurbishment Notification

352

6.4.3 Material Requirements Planning

353

6.4.4 Refurbishment Order

355

6.4.5 Goods Issue

356

6.4.6 Goods Receipt

357

6.4.7 Costing

357

6.5 Subcontracting

359

6.5.1 Subcontracting Order

360

6.5.2 Purchase Requisition

361

6.5.3 Subcontracting Monitor

362

6.5.4 Serial Numbers

364

6.6 Test Equipment Calibration

365

6.6.1 Equipment

366

6.6.2 Inspection Characteristics

367

6.6.3 Task List

368

6.6.4 Maintenance Plan

371

6.6.5 Order and Inspection Lot

372

6.6.6 Results Recording

373

6.6.7 Usage Decision

374

6.6.8 Follow-Up Actions

374

6.7 Follow-On Order and Follow-On Notification

375

6.7.1 Direct Creation of Follow-On Notifications

375

6.7.2 Direct Creation of Follow-On Orders

376

6.7.3 Indirect Creation of Follow-On Orders and Follow-On Notifications

376

6.8 Pool Asset Management

378

6.8.1 Request

379

6.8.2 Scheduling via Planning Board

380

6.8.3 Confirmation

381

6.8.4 Issue

382

6.8.5 Return

383

6.8.6 Settlement

383

6.8.7 Prerequisites

383

6.9 Project-Based Maintenance

384

6.9.1 Project System

385

6.9.2 Revision

390

6.9.3 Planning Buckets

392

6.10 Checklists

395

6.10.1 Basic Checklist Solution

396

6.10.2 Enhanced Checklist Solution

398

6.10.3 Comparison Between Basic and Enhanced Checklist Processing

407

6.11 Work Order Cycle with Phase Model

408

6.11.1 Basics of the Phase Model

408

6.11.2 The Nine Phases

410

6.11.3 Comparison

417

6.12 Billed Maintenance

419

6.12.1 Billed Maintenance with Advanced Execution

420

6.12.2 Advanced Functions

422

6.12.3 Benefits and Recommendations

423

6.13 Summary

423

7 Integration of Applications from Other Disciplines

425

7.1 Integration Within SAP S/4HANA

426

7.1.1 Materials Management

427

7.1.2 Production Planning and Controlling

434

7.1.3 In-House Production of Spare Parts for Stock

438

7.1.4 Quality Management

442

7.1.5 Financial Accounting

443

7.1.6 Asset Accounting

444

7.1.7 Controlling

447

7.1.8 Flexible Real Estate Management

456

7.1.9 Human Capital Management

458

7.2 Integration with Other SAP Systems

462

7.2.1 SAP Master Data Governance

463

7.2.2 SAP Supplier Relationship Management

465

7.2.3 SAP Ariba

467

7.3 Integration with Non-SAP Systems

471

7.3.1 Operations Monitoring Systems

472

7.3.2 Operations Information Systems

474

7.4 Summary

476

8 Plant Maintenance Controlling

479

8.1 What's Involved in Plant Maintenance Controlling

479

8.2 SAP Tools for Obtaining Information

483

8.2.1 SAP List Viewer

483

8.2.2 SAP Fiori Dynamic Lists

490

8.2.3 QuickViewer

492

8.2.4 Logistics Information System

497

8.2.5 SAP Business Warehouse

502

8.2.6 SAP Analytics Cloud

510

8.2.7 Comparative Overview

515

8.3 SAP Tools for Budgeting

517

8.3.1 Order Budgeting

518

8.3.2 Cost Center Budgeting

519

8.3.3 Budgeting Using Investment Management Programs

521

8.3.4 Budgeting Using Work Breakdown Structure Elements

524

8.4 Summary

527

9 Innovations in Maintenance Technology

529

9.1 Mobile Maintenance

529

9.1.1 Basics of Mobile Maintenance with SAP

530

9.1.2 SAP Fiori Apps for Mobile Maintenance

531

9.1.3 SAP Service and Asset Manager

532

9.1.4 Comparison of SAP Service and Asset Manager and SAP Fiori Apps

543

9.1.5 Practical Examples

545

9.2 SAP Business Network Asset Collaboration

546

9.2.1 What Is SAP Business Network Asset Collaboration?

546

9.2.2 Cloud-Based Functions

548

9.2.3 Integration in SAP S/4HANA

554

9.2.4 Underlying Technology

555

9.2.5 Application Scenarios

556

9.2.6 Requirements and Getting Started

558

9.3 SAP Asset Performance Management

559

9.3.1 SAP Business Technology Platform as the Foundation

560

9.3.2 Central Data Foundation and Object View

562

9.3.3 Industrial Systems

563

9.3.4 Risk- and Strategy-Based Maintenance

565

9.3.5 Condition- and Rule-Oriented Maintenance

568

9.3.6 Condition Monitoring and Embedded Internet of Things

571

9.4 Artificial Intelligence in Maintenance

573

9.4.1 What Is Artificial Intelligence?

573

9.4.2 Rationale for AI in Maintenance

574

9.4.3 Use Cases in Maintenance

576

9.4.4 Joule: The AI Copilot

580

9.4.5 Technical and Organizational Prerequisites

582

9.4.6 Limits and Challenges

584

9.5 Summary

586

10 Usability

587

10.1 Basics

588

10.1.1 What Is Usability?

588

10.1.2 How Usability Can Be Assessed

592

10.1.3 Why Usability Does Not Mean User Acceptance

593

10.1.4 Why Is User Acceptance So Important in Plant Maintenance?

595

10.1.5 SAP System Options to Improve Usability

597

10.2 User’s Options to Improve Usability

598

10.2.1 General User Parameters and Default Values

598

10.2.2 Maintenance-Specific User Default Values

602

10.2.3 Roles, Favorites, and My Home

608

10.2.4 List Variants and Dynamic Lists

610

10.2.5 Personal Value List

610

10.2.6 Buttons and Key Combinations

611

10.2.7 Table Controls and My Views

612

10.3 Non-Programming Options to Improve Usability

615

10.3.1 Transaction Variants

615

10.3.2 Customizing

617

10.3.3 Action Box

621

10.3.4 Mobile Solutions

622

10.3.5 SAP Fiori

623

10.3.6 Adapting the SAP Fiori UI at Runtime

624

10.3.7 SAP Screen Personas

627

10.4 Programming Options to Improve Usability

630

10.4.1 Upstream Transactions

631

10.4.2 Business Application Programming Interfaces

632

10.4.3 Web Interface

633

10.4.4 Customer Exits

635

10.4.5 Custom Fields and Custom Logic

638

10.4.6 Other Programming Techniques

639

10.5 Usability Study 1: SAP GUI With and Without Tuning

641

10.5.1 Preparation

642

10.5.2 Execution

644

10.5.3 Results

645

10.6 Usability Study 2: SAP GUI and SAP Fiori

649

10.6.1 Preparation

649

10.6.2 Execution

653

10.6.3 Results

654

10.7 Summary

660

B Overviews

669

B.1 SAP Fiori Apps with SAPUI5 Technology

669

B.2 SAP Fiori Apps with Web Dynpro Technology

672

B.3 Functional Comparison of Structuring Resources

673

B.4 Functions of Notifications and Orders

674

B.5 Integration Aspects

678

B.6 Standard Plant Maintenance Information System Reports

684