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)

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)

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)

Key T-codes

Critical Fields (QMEL + QMIH Tables)

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

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

Critical Fields (AUFK + AFKO + AFIH Tables)

Operations & Component Planning

Operations (AFIH table) — individual tasks within maintenance order

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)

Plan Types

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)

Task Lists for Maintenance (IA01/IA05)

Reusable checklists & instructions

Task list structure (PLKO + PLPO)

• Header: task list ID, description, equipment/FL applicable
• Operations: step 10, 20, 30... each with work center + time + materials

Example: Pump Inspection Task List (TASKLIST-PUMP-INSPECT)

Step 10: Visual inspection (0.5 hrs, work center: MAINT_VISUAL)
Step 20: Vibration check (1.0 hr, equipment: VIBRATION_METER)
Step 30: Temperature measurement (0.5 hrs, sensor: TEMP_PROBE_001)
Step 40: Oil sampling (0.25 hrs, material: OIL_SAMPLE_BOTTLE)
Step 50: Report findings (0.5 hrs, work center: MAINT_ADMIN)
Total: 2.75 hours

7. Maintenance Scheduling (IP10 / IP30)

IP10 — Call Object Scheduling

Generates notifications/orders based on maintenance plans

• Input: maintenance plans (IP01) + current equipment state
• Output: QMEL (notifications) or AUFK (orders) for upcoming maintenance
• Run frequency: typically nightly batch (transaction SM36)

IP30 — Deadline Monitoring

Tracks which equipment is overdue for maintenance

Usage:

• Filter by: planning plant, work center, priority
• Action: create maintenance orders (IW31) for overdue items

Counter Readings (QMSREC Table)

Equipment counters — track usage-based maintenance triggers

Recording counter reads:

• QM04: Single equipment counter read
• QM05: Multiple counters (batch entry)
• Readings feed into IP10 scheduling → if counter >= threshold, create notification

8. Breakdown Maintenance & MTBF/MTTR

Breakdown Notification Entry (IW21)

Operator or manager reports failure:

1. IW21 → Equipment/FL + Damage code + Priority
2. System creates notification (e.g., NOTIF-2024-001234)
3. Assign to maintenance team (ARBPL — work center)
4. Create order (IW31 with order type PM02)
5. Release order (RELD status) → work begins
6. Confirm completion (CO11N) → TECO
7. Settle order (KO88) → cost posted

Malfunction Start/End Time (QMEL / QMIH)

Downtime calculation:

• Total Downtime = FZEND - MERDAT
• Repair Time (MTTR) = FZEND - FZDAT
• Waiting Time = FZDAT - MERDAT (can indicate logistics delay)

MTBF (Mean Time Between Failures) Calculation

Formula: Total Equipment Uptime / Number of Failures

Uptime period: INBDT (startup date) to current date or end date

Failure count: Sum of notifications with SCHAD = malfunction codes

SAP tracking:

• EQUI-INBDT: equipment startup date
• QMEL count by equipment (table function: SELECT COUNT(*) FROM QMEL WHERE EQUNR = 'PUMP-001')
• MTBF = (days_operating) / (failure_count)

Example:

• Equipment MOTOR-001 startup: 2022-01-01
• As of 2024-04-12: 861 days operating
• Malfunction notifications: 12 failures
• MTBF = 861 days / 12 = 71.75 days average between failures

MTTR (Mean Time To Repair) Calculation

Formula: Total Repair Time / Number of Repairs

Repair time sourced:

• AUFK.FZEND - AUFK.FZDAT (actual hours spent on repair)
• Includes: labor hours (CO11N) + external service time (if PO-based)

SAP tracking:

• Table AUFK: all PM02 (breakdown) orders
• Filter: EQUNR = equipment + ORDER_TYPE = PM02
• Calculate: SUM(FZEND - FZDAT) / COUNT(*) = MTTR

Example:

• Motor MOTOR-001: 8 breakdowns over 12 months
• Total actual repair hours logged: 44 hours
• MTTR = 44 / 8 = 5.5 hours per breakdown

KPI Reporting (IW28/IW29)

IW28 — Notification Listing

• Standard SAP query: All notifications with filters (date range, equipment, status)
• Output: Excel-friendly listing with damage code, priority, creation date, completion date

IW29 — Notification Analysis (OLAP)

• Multidimensional analysis: Equipment × Damage Code × Month
• Drilldown: which equipment/codes are failure-prone
• Used to drive preventive maintenance plan decisions

9. Refurbishment & Serial Number Management

Equipment Refurbishment (Instandsetzung)

Complete overhaul of equipment — treated as major maintenance project

Order type: PM03 or special project order

Process:

1. Create maintenance order (IW31, order type PM03)
2. Assign refurbishment checklist (task list IA05)
3. GI all old/faulty parts (MIGO 261)
4. GR refurbished components (MIGO 101)
5. Update equipment master with new serial numbers if components replaced (IE02)
6. Confirmation (CO11N) → record actual hours + components replaced
7. Settlement (KO88) → post refurb cost to internal order or asset

Serial Number Management (SERGE / EQUI-SERGE)

Link between equipment and material master (MATNR)

Setup in Material Master (MM01)

• Org level: Plant
• Accounting view: Valuation class + Serial Number Profile (MMSL field)
• Serial Number Profile (MMSL):
  • Determines if serial numbers are required (batch posting) or optional (normal)
  • e.g., MMSL = "001" → Serial number required for all GR/GI of this material

Recording Serial Number in Equipment (IE01/IE02)

Field: EQUI-SERGE (equipment serial number)

• Max 30 chars
• Validated against material's serial number profile
• Used in: warranty tracking, spare parts traceability, recall management

Serial Number Change History (EQUZ)

Automatic log in EQUZ table

• Timestamp, user ID, old serial → new serial
• Useful for: component replacement audits, warranty period recalculation

Example: Motor Refurbishment Event

• Equipment MOTOR-001, Original Serial: "MOT-12345-ABC"
• Refurb replaces motor, New Serial: "MOT-67890-XYZ"
• EQUZ records: Date, User, Field=SERGE, Old=MOT-12345-ABC, New=MOT-67890-XYZ
• Warranty restart: if refurb qualifies, set INBDT to refurb completion date

10. PM-CO Integration & Cost Collection

Settlement (KO88)

Posts maintenance costs from AUFK to receiver (cost center or internal order)

Key T-codes:

• KO88: Settle individual order
• KO8G: Settle multiple orders (batch)
• KO8K: Maintain settlement rule (assignment of order type → receiver type)

Settlement Rule Setup (SPRO → Controlling → Orders → Settled Costs)

Variance Calculation (KO88 — Simulate before Actual)

Variance categories:

1. Input price variance (ABV): Material cost differences (actual price ≠ standard price)
2. Input quantity variance (AMV): More/fewer materials used
3. Overhead variance (SCRAP): Overhead surcharge % deviation
4. Remaining input (RESTINPUT): Unconfirmed costs still open

Best practice:

• Always run KO88 with "Simulate" first (F8 or simulation button)
• Review variance report → approve variances if acceptable
• Run actual settlement separately → creates FI documents (Controlling: 1200 Maintenance Costs)

Cost Planning (KALKULATIONSSCHEMA)

Annual maintenance budget planning — by equipment category, order type, cost center

Example budget structure:

• Category: Motors → Preventive (PM01) budget = 50,000 EUR
• Category: Motors → Breakdown (PM02) budget = 30,000 EUR (contingency)
• Total annual motor maintenance budget = 80,000 EUR

Tracking:

• AUFK-KOSTL → cost center commitment
• Monthly report (S_ALR_87013612 — Cost Center Actual vs. Budget) → compares maintenance spend vs. plan

11. ECC vs S/4HANA — PM Specific Differences

12. 한국 현장 특이점 (Korean Manufacturing Context)

삼성/LG/현대 공장의 SAP PM 운영 특징

설비 가동률 (Equipment Availability) 관리

• 한국 제조 표준: 최소 95% 가용율 목표 (글로벌 85% vs)
• 목표 달성: 예방보전 비율 70%, 고장정비 비율 30% 이상
• SAP tracking: IW29 → "설비가동 중단 시간 분석" 월간 report (OEE 연계)

3교대 근무 환경에서의 설비 관리

• Maintenance team: 24시간 교대근무 (Day / Evening / Night shifts)
• Notification 입력: 실시간 (각 라인의 작업자 → QMS 담당자 → PM팀에 자동 통보)
• 야간 고장 처리: 긴급 외주(Emergency Vendor) 연동 (AUFK.AUART = ER01)
• 근무 시간 외 작업 (야간할증 30%): CO11N 확인 시 "야간작업" 활동코드로 구분

안전관리와 PM 법적 연계 (산업안전보건법 제23조)

• 설비점검 이력: 무조건 5년 보관 (SAP Archive에 IW28 스냅샷)
• 부정기 점검 기록: QMEL-AUFK 링크 완전성 검증 필수 (감시원 감사 대비)
• 위험설비 (크레인, 보일러, 압력용기): 고용노동부 특별감시 → PM과 QM 완전 통합
  • 고장코드 SCHAD = "PRESSURE_RELIEF_FAIL" 발생 시 자동으로 QM 검사 오더(QM10) 생성
  • AUFK → QAIN (inspection) → 외부검사기관 위탁 처리

MES ↔ SAP PM 실시간 연동

• MES (현대 DAPS, LG MES) → 설비 상태 센서 데이터 → 5분 간격 HTTP/SOAP 호출
• SAP BAPI: BAPI_EQUI_SET_COUNTER → Equipment counter 자동 갱신
• Trigger: Counter >= Preventive Maintenance Threshold → IP10 자동 IP30 Yellow 상태 전환
• Example: Motor operating hours 10,000 threshold → MES 전송 → SAP 자동 "점검 예정" notification

외주 보전 관리 (Contract Maintenance with Vendors)

• 전문 정비업체 위탁: AUFK.AUART = PM10 + Purchase Order (ME21N) 연동
• 위탁사 작업 추적: Vendor EQUI-MFBF (equipment responsibility matrix) → 정기 외주사별 KPI 평가
• 비용: PO line → GR (MIGO 101 services) → IV (MIRO) → Cost analysis (KO88 settle to cost center)

설비별 소비자부품 (Consumable Parts) 자동 발주

• 고빈도 부품: 오일, 필터, 그리스, 밀폐제 등
• PM 예방점검 task list → 필요 부품 자동 생성 (AUFK → PR → PO auto-release)
• Example: IP01 "Monthly bearing maintenance" → Task List에 "10kg Lubricant XYZ" 지정
• → IP10 실행 시 자동으로 PR 생성 → 구매 부서 자동 승인 (workflow) → PO release

설비 성능 성과금(Incentive) 관리

• KPI 연계: MTBF ≥ 90 days → PM팀 보너스 10%, MTTR ≤ 4 hours → +5%
• 월간: IW29 OLAP → Equipment별 MTBF/MTTR 계산 → 급여 시스템(HR) 연동 (BAPI_PAYROLL_PROCESS)

설비 감가상각과의 연계 (Asset Management Integration)

• Equipment EQUI-MATNR → Asset Master (AA) 자동 링크 (S/4: AA → FIAA table)
• Maintenance cost tracking: AUFK 누적비용 / Asset net book value > 60% → 기업회계 기준 "경영상 결정" 입력
• Example: Motor 구입가 100,000 EUR, 누적 maintenance cost 63,000 EUR → 신규 구입 검토 요청

13. Standard Response Format

Follow sapstack Universal Rules:

Issue → Root Cause → Check (T-code + Table.Field) → Fix (Steps) → Prevention → SAP Note

Example: "Equipment shows MTBF 15 days — why so low?"

Issue: Motor MOTOR-001 has 8 failures in 4 months (MTBF = 15 days)

Root Cause Hypotheses:

1. Wrong damage/cause codes → notifications clustered by operator error
2. Operator misuse (overloading) → URSACHE = USER_ERROR
3. Design defect or component batch issue → QMSM-SERGE links to defective serial lot
4. Preventive maintenance never executed → check IP30 deadline monitoring

Check:

IE03 → MOTOR-001 → Equipment History tab (EQUZ)
IW24 → Filter EQUNR=MOTOR-001, date range 4 months
  → Count notifications (QMNUM)
  → Examine QMIH-URSACHE field (root cause codes)
IW28 → Report "Failure Frequency by Equipment & Cause"
  → Identify if URSACHE concentrated (indicates pattern)
IP30 → Search MOTOR-001
  → Check if any preventive tasks overdue (RED status)

Fix (if preventive maintenance overdue):

1. IP01 → Find assigned maintenance plan for MOTOR-001
2. IP10 → Force run "Deadline monitoring for plant ZPLANT"
3. Create overdue notifications for missed deadlines
4. Assign maintenance orders (IW31) + release (RELD)
5. Schedule work teams

Fix (if root cause = design defect):

1. Create RFC ticket with equipment vendor
2. Escalate to engineering (via AUFK internal order for redesign project)
3. Flag equipment in IE02 with equipment status "Restricted" (IFLOTA flag)
4. Increase spare parts stock (MM41) until replacement arrives

Prevention:

• Establish PM02 order type cost tracking → identify underbudgeted equipment
• Monthly review: IW29 MTBF by equipment class → correlate with age/design
• Upgrade task lists (IA05) → add inspection interval reduction for high-MTBF items
• Training: operator notification accuracy (damage codes) via HR learning module

SAP Notes (if applicable):

• Check SAP Support Portal (OSS) for "equipment MTBF analysis" + equipment model

14. References

• references/ko/quick-guide.md — Maintenance order creation workflow (fast path)
• references/ko/SKILL-ko.md — Korean field language guide for PM terms
• SAP Help: SAP PM module documentation (https://help.sap.com/docs/SAP_S4HANA_CLOUD/plant_maintenance)
• Configuration: SPRO → Plant Maintenance (all customization)
• Table documentation: EQUI, IFLO, QMEL, AUFK, IP01 (F1 in SAP GUI)