sap-pm

## 1. Environment Intake Checklist Before answering PM questions, collect: - **SAP Release**: ECC 6.0 (which EhP?) or S/4HANA (which release year?) - **Deployment model**: On-premise / RISE / Cloud Public Edition - **PM Organization**: Planning Plant, Maintenance Plant, Maintenance Coordination Plant - **Industry sector**: Manufacturing (automotive, chemicals, electronics), energy, pharma, food & beverage - **Equipment strategy**: Single-level (equipment only) vs. two-level (equipment + functional locations) - **Maintenance type focus**: Breakdown, preventive, predictive, contract, or combination? - **Integration requirements**: MES, predictive maintenance (PAI), mobile (SAP Asset Manager), analytics --- ## 2. Equipment Master Data (IE01/IE02/IE03) ### Equipment Creation (IE01) **Key T-codes & Menu Path** - IE01: Create Equipment (SPRO → Plant Maintenance → Master Data → Equipment → Create) - IE02: Change Equipment - IE03: Display Equipment - IE10: Create Fleet (for mass equipment with identical configuration) ### Critical Fields (EQUI Table) | Field | Meaning | Mandatory | Notes | |-------|---------|-----------|-------| | EQUNR | Equipment number | Y | Unique 18-char ID; can be internal/external assigned | | EQKTX | Equipment description | Y | 40 chars; recommend English + Korean | | EQART | Equipment category | Y | PUMPE (pump), MOTOR (motor), KOMPR (compressor) etc. | | MATNR | Material master | N | Links to inventory; if serial-tracked material, serializes equipment | | SERGE | Serial number | N | Hardware serial from nameplate; used in warranty tracking | | HEQUI | Higher-level equipment | N | Parent equipment (e.g. pump is part of production line) | | ILOAN | Functional location | Y | Must exist in IFLO before assignment | | MANDT | Company code | Y | Set at creation; cannot change | | WERKS | Plant | Y | Maintenance-executing plant | | KMFID | Manufacturer | N | Free-text; recommend SAP vendor master LIFNR | | GEWICHT | Weight | N | For spare parts estimation | | INBDT | Startup date | N | Important for MTBF calculation period | ### Equipment Classification Table KLAH (classification header) + KLASP (assignment): - Class type: EQUIPMENT, ZEQUIP (custom) - Characteristics: Model, Manufacturer, Voltage, Capacity, Brand - Used for: spare parts list filtering, maintenance strategy assignment, reporting ### Serial Number Management - Equipment must link to material master (EQUI.MATNR) - Material → Accounting 1 view → Valuation Class + Serial Number Profile (MMSL) - Serial Number Profile (MMSL): defines when system forces serial entry during GR, GI, MIGO - Equipment History (EQUZ): automatic log of changes (creation, equipment change, tag changes) ### Equipment Deletion - Equipment cannot be deleted if it has maintenance history (QMEL, AUFK exist) - Workaround: Flag EQUI-LOEKZ (deletion flag) = X → equipment hidden in selection, kept for history --- ## 3. Functional Location Master Data (IL01/IL02/IL03) **Hierarchical structure** — represents plant's physical/logical organization ### Functional Location Creation (IL01) **Key T-codes** - IL01: Create Functional Location (SPRO → Plant Maintenance → Master Data → Technical Objects → Functional Location) - IL02: Change Functional Location - IL03: Display Functional Location ### Hierarchy Example (Two-Level Strategy) ``` Production Line A (ZFUNCLOC-PRODLINE-A) ├─ Section 1 (ZFUNCLOC-PRODLINE-A-SEC1) │ ├─ Equipment: Motor, Pump, Control Panel └─ Section 2 (ZFUNCLOC-PRODLINE-A-SEC2) ├─ Equipment: Conveyor, Sensor ``` ### Critical Fields (IFLO + IFLOT Tables) | Field | Table | Meaning | Notes | |-------|-------|---------|-------| | TPLNR | IFLO | Functional location ID | 40-char hierarchical, e.g., PROD-001-002 | | TXTMI | IFLOT | Description (multilingual) | Store in DE, EN, KO | | FLTYP | IFLO | Functional location type | e.g., PUMPING_STATION, MOTOR_ROOM | | GEWRK | IFLO | Responsible work center (PM team) | Links to CR01 work center | | HFLOC | IFLO | Higher-level functional location | Parent node | | STRNO | IFLO | Building/hall number | Organizational reference | | MANDT | IFLO | Company code | Assigned at creation | ### Account Assignment - Cost center (KOSTL): for cost tracking of maintenance labor + materials - Internal order (AUFNR): for project-based maintenance (e.g., annual overhaul) - Profit center: for P&L attribution - WBS element: for capital project maintenance --- ## 4. Maintenance Notification (IW21/IW22/IW23) **Entry point for all maintenance requests** — whether breakdown or planned ### Notification Types (QMNUM Table) | Notification Type | ID | Trigger | Example Use Case | |-------------------|----|---------|----| | Malfunction (고장) | M1 | Breakdown reported by operator | "Motor stopped working" | | Maintenance request | M2 | Preventive or user-initiated task | "Annual pump inspection needed" | | Activity report (업무보고) | M3 | Post-maintenance completion record | "Replaced bearings on motor" | | Calibration notification | M4 | Instrument calibration schedule | "Pressure gauge needs recalibration" | ### Key T-codes | T-code | Description | |--------|-------------| | IW21 | Create notification | | IW22 | Change notification | | IW23 | Display notification | | IW24 | List of notifications (selection) | | IW28 | Notification listing (reporting) | | IW29 | Notification analysis (OLAP) | ### Critical Fields (QMEL + QMIH Tables) | Field | Table | Meaning | Max Length | |-------|-------|---------|-----------| | QMNUM | QMEL | Notification number | 12 digits (internal/external assigned) | | QMTXT | QMEL | Short description | 40 chars | | LTXT | QMEL | Long text | 2500 chars (ALV memo) | | EQUNR | QMEL | Equipment or... | 18 chars | | TPLNR | QMEL | Functional location | 40 chars (either EQUNR or TPLNR required) | | SCHAD | QMEL | Damage/fault code | 4 chars; must exist in custom table (e.g., ZMAINTCODES) | | URSACHE | QMIH | Root cause code | 4 chars; ABAP table maintained via SPRO | | AKTIVITAET | QMIH | Activity code (work type) | 4 chars; e.g., REPAIR, INSPECT, REPLACE | | ANLDAT | QMEL | Notification creation date | Auto-filled | | MERDAT | QMEL | Reported date/time | User-entered (when problem was discovered) | | PRIO | QMEL | Priority (1=urgent, 4=low) | Links to SLA | | ARBPL | QMEL | Assigned work center | CR01 resource pool | | AUART | QMIH | Associated order type | e.g., PM01, PM02 (links to maintenance order) | ### Damage Code & Root Cause Workflow **Damage codes (Schädigungen)** → categorize **what broke** - Table maintained in: SPRO → Plant Maintenance → Notification → Configure Notification Type → Damage Codes - Example: BEARING (Lagerschaden), SEAL (Dichtungsschaden), MOTOR_COIL (Motorwicklung) **Root cause codes** → categorize **why it broke** - Maintained in: SPRO → Plant Maintenance → Notification → Configure Notification Type → Cause Codes - Example: OVERLOAD (Überbelastung), POOR_MAINTENANCE (Schlechte Instandhaltung), DESIGN_DEFECT **Activity codes** → actions taken - INSPECTION, REPAIR, REPLACEMENT, ADJUSTMENT, CALIBRATION ### Notification Workflow ``` IW21 (Create) → IW22 (Edit, assign to equipment/FL) → Create Maintenance Order (IW31) or Assign Existing (IW81) → Complete Notification (IW21 → Status = COMPLETED) → Archive / History Report (IW28, IW29) ``` --- ## 5. Maintenance Order (IW31/IW32/IW33) **Execution unit** — operationalizes a notification into scheduled work with costing ### Order Types & Lifecycle | Order Type | Purpose | Settlement | Workflow | |-----------|---------|-----------|----------| | PM01 | Preventive maintenance | Cost center or internal order | Recurring | | PM02 | Breakdown maintenance | Cost center or internal order | Ad-hoc | | PM03 | Corrective action / temporary fix | Internal order | One-time | | PM10 | Maintenance by vendor/contract | Purchase order line | Outsourced | | ER01 | Emergency order (fast-track) | Cost center | Expedited release | ### Lifecycle (Status Flow) ``` CRTD (Created) → PLAN (Planning) → RELD (Released) → TECO (Technically Complete) → CLSD (Closed) ``` **Key transitions:** - CRTD → RELD: IW32 (Change) → Release button (Authorization: PM.ORD.R) - RELD → TECO: CO11N (confirmation) or manual in IW32 - TECO → CLSD: Settlement (KO88) → automatic CLSD after successful posting ### Key T-codes | T-code | Description | |--------|-------------| | IW31 | Create maintenance order | | IW32 | Change maintenance order | | IW33 | Display maintenance order | | IW38 | Maintenance order list (with statuses) | | IW39 | Maintenance order analysis (OLAP) | | COOIS | Production order info system (includes maintenance orders) | ### Critical Fields (AUFK + AFKO + AFIH Tables) | Field | Table | Meaning | Key Link | |-------|-------|---------|----------| | AUFNR | AUFK | Maintenance order number | 12 digits | | AUART | AUFK | Order type (PM01, PM02...) | Defines cost collection rules | | EQUNR | AUFK | Equipment | Equipment master (EQUI) | | TPLNR | AUFK | Functional location | FL master (IFLO) | | QMNUM | AUFK | Notification reference | Notification (QMEL) | | KOSTL | AUFK | Cost center (account assignment) | GL posting account | | INAUFNR | AUFK | Internal order (account assignment) | Alternative to cost center | | ERDAT | AUFK | Creation date | Audit trail | | GSTDT | AUFK | Scheduled start date | Capacity planning | | GETDT | AUFK | Scheduled end date | Capacity planning | | FZDAT | AUFK | Actual start date | Filled by TECO or confirm | | FZEND | AUFK | Actual end date | Filled by TECO or confirm | | GGRTXT | AUFK | Order description | 40 chars | | MGVST | AUFK | Total planned labor hours | Sum of operations (AFIH.LAH) | | STATUS | JEST | Order status (via object key AUFK + status cat P) | Links to JEST table (status management) | ### Operations & Component Planning **Operations (AFIH table)** — individual tasks within maintenance order | Field | Meaning | Type | |-------|---------|------| | LTEXT | Operation description | Text, e.g., "Replace pump seal" | | LAH | Standard labor hours | Decimal, e.g., 4.5 | | MGH | Standard machine hours | Used for resource capacity planning | | ARBPL | Work center | CR01 resource (e.g., MAINT_TEAM_A) | | LTXA | Operation long text | Detail work instructions | **Components (BOM link)** — spare parts required - AFIH → STPO (BOM item) → material + quantity - Component status: Available / Withdrawn / On PO / Missing (CO24) - Backflush: if enabled, components auto-issue at confirmation (MIGO 261 automatic) ### Maintenance Labor & Costs **Labor hours collection (CO11N confirmation)** - Actual labor time entered at operation level - Overtime multipliers applied (customizable per order type) **Spare parts cost (MIGO)** - GI from warehouse → MIGO 261 → charged to maintenance order - Vendor-supplied parts → PO line → GR → invoice → cost posting **Overhead allocation (KO88)** - Settlement rule: Actual cost + overhead (%) → Cost center or internal order - Example: Order cost = 5,000 EUR → + 20% overhead = 6,000 EUR → posted to cost center ### External Services (Subcontracting) - Maintenance order header → Services tab → Create purchase requisition (BANF) - Service material type: automatically creates PR → RFQ → PO → GR → IV (MIRO) - Typical service materials: OUTSOURCE_REPAIR, INSPECTION_LABOR --- ## 6. Preventive Maintenance (IP01/IP10/IP30) **Automated scheduling of recurring maintenance tasks** ### Maintenance Plans (IP01/IP02) | T-code | Description | |--------|-------------| | IP01 | Create maintenance plan | | IP02 | Change maintenance plan | | IP03 | Display maintenance plan | | IP10 | Call object scheduling (run planner) | | IP30 | Deadline monitoring | ### Plan Types | Plan Type | Trigger Condition | Interval | |-----------|-------------------|----------| | Time-based (Z1) | Calendar days | e.g., every 30 days, every 1 January | | Counter-based (Z2) | Equipment counter (QMSREC) | e.g., every 10,000 operating hours | | Multiple-counter (Z3) | Multiple counters (e.g., hours + days) | Whichever comes first | | Performance-based (Z4) | Equipment performance KPI | e.g., when efficiency drops below 95% | ### Maintenance Strategy (IP11) **Strategy = grouping of maintenance tasks** → optimize scheduling Example: **Monthly production line maintenance (STRAT_PRODLINE_M)** - Task 1: Bearing lubrication (5 hours, cost center MAINT_OIL) - Task 2: Filter replacement (3 hours, material M-FILTER-001, cost center MAINT_PARTS) - Task 3: Inspection (4 hours, cost center MAINT_LABOR) - Total plan: 12 labor hours, materials + labor cost per execution ### Scheduling Strategy (IP11 → PLTYP / IPRFL Table) | Field | Meaning | Example | |-------|---------|---------| | BESCHREIBUNG | Strategy name | "MOTOR_BEARING_MAINTENANCE" | | MPLNR | Maintenance plan number | "MPLAN-MOTOR-001" | | IPRFL | Task list (group of tasks) | "TASKLIST-BEARING-005" |