Maximize Your Plant Maintenance with SAP

John W. Hoke has served in many roles beginning with project engineering and management, through plant maintenance and operations leadership, and most recently involved annual outage management and internal consulting. He is well versed in operational and maintenance performance metrics and improvement methodologies. He has also performed various leadership roles in Work Design for Operations, Maintenance, and Stores units. In 2003, John received SAP Plant Maintenance Consultant Certification by SAP America and in 2005, he also received his Certified Maintenance and Reliability (CMRP) designation. This knowledge is used to tie together a comprehensive package suited to help lead improvement in all aspects of manufacturing maintenance. Lorri Craig was a poweruser and a leader in the SAP implementation in a major pulp and paper facility. Her roles included teaching and coaching in the SAP Plant Maintenance, Human Resources, and CATS modules. She has developed training packages for craftsmen and first line supervisors for maintenance planning, scheduling, and time keeping. Lorri has scheduled outages in Microsoft Project for the past 10 years. She also has served on Maintenance Redesign Teams to improve organizational effectiveness.

1 ... The Maintenance Health Assessment ... 21
... 1.1 ... Maintenance Needs a Computerised Maintenance Management System ... 22
... 1.2 ... The Required Mindsets for Reliability Success ... 25
... 1.3 ... The Methodology of Reliability Success ... 29
... 1.4 ... The Skills that Drive Reliability Success ... 34
... 1.5 ... Testing for SAP PM Readiness ... 38
... 1.6 ... Summary ... 41

2 ... SAP PM Basic Knowledge ... 43
... 2.1 ... The True Return on Investment of SAP PM ... 43
... 2.2 ... SAP Overview from a Plant Maintenance Perspective ... 48
... 2.3 ... Beginning with an End in Mind ... 57
... 2.4 ... The SAP Software Hierarchy ... 61
... 2.5 ... Evolving from the Newspaper Culture to the Internet Culture ... 72
... 2.6 ... Envision an Effective Implementation ... 77
... 2.7 ... Summary ... 79

3 ... SAP PM Education ... 81
... 3.1 ... How Ineffective Training Will Manifest Itself ... 81
... 3.2 ... Dealing with Audience Diversity ... 82
... 3.3 ... How to Educate and Train at the Same Time ... 84
... 3.4 ... SAP PM Teaching Tools ... 88
... 3.5 ... Train the Trainer Methodology ... 92
... 3.6 ... Testing for and Expecting Knowledge ... 94
... 3.7 ... Summary ... 96

4 ... Successful SAP PM Techniques ... 99
... 4.1 ... What Systems Require Continuous Support ... 99
... 4.2 ... Managing the Pace of Effective Support ... 110
... 4.3 ... This Is a Healthy SAP PM Installation ... 113
... 4.4 ... Job Descriptions and Skills Needed ... 121
... 4.5 ... Summary ... 123

5 ... Technical Object Structure Functionality Setting the Foundation ... 125
... 5.1 ... Dependable Technical Object Structure Benefits ... 125
... 5.2 ... Technical Object Functionality ... 131
... 5.3 ... Common Application and Configuration Opportunities ... 151
... 5.4 ... Summary ... 162

6 ... Capturing the Reliability History Needed To Improve ... 163
... 6.1 ... Why Having a Dependable Notification Process is Important ... 163
... 6.2 ... Notification Functionality ... 166
... 6.3 ... Notification Application Design and Configuration Overview ... 187
... 6.4 ... Summary ... 206

7 ... Effective Planning, Execution, and Improvement of Maintenance Work ... 209
... 7.1 ... How the Maintenance Order Contributes to the Reliability Improvement Effort ... 209
... 7.2 ... Order Design and Configuration Overview ... 211
... 7.3 ... Order Application Overview Work Order Application ... 238
... 7.4 ... Common Application and Configuration Opportunities ... 259
... 7.5 ... Summary ... 268

8 ... Implementing an Effective SAP Plant Maintenance Preventive Maintenance Strategy ... 269
... 8.1 ... Why Having a Good Preventive Maintenance Process Tool is Important ... 269
... 8.2 ... SAP Preventive Maintenance Functionality ... 271
... 8.3 ... SAP Preventive Maintenance Application ... 283
... 8.4 ... Common Configuration and Application Barriers ... 296
... 8.5 ... Summary ... 300

9 ... Getting the Most Out of Your SAP Plant Maintenance Data ... 303
... 9.1 ... The Value of Data in SAP PM ... 303
... 9.2 ... Customised SAP Reporting Available to SAP PM ... 309
... 9.3 ... The Plant Maintenance Information System ... 312
... 9.4 ... Reporting Application of Selection Screens and List Displays ... 322
... 9.5 ... Summary ... 340

10 ... Measuring SAP Plant Maintenance Performance Health ... 341
... 10.1 ... You Get What You Measure ... 341
... 10.2 ... SAP Effectiveness Metrics ... 342
... 10.3 ... Summary ... 360

A ... The Authors ... 363