SAP R3 Plant Maintenance SAP Korea SAP Korea
- Slides: 57
SAP R/3 Plant Maintenance SAP Korea ã SAP Korea 2000 / 1
PM Integration Outside SAP CO - Cost center Controlling - Order Settlement - 자재마스터 - Shutdown 정비 - 재고관리 신규/Upgrade 공사 - 자재/외주 구매 - 예산/비용 - 계약 - Scheduling MM - SCADA C - DCS/PCS S - CMS P - CAD - GIS C PM AM - 자산마스터 - 감가상각 - 자본화 S P PS - 마스터데이타 - 자원(작업자, 자재, 도구) - Planning & Scheduling - Processing of tasks - 이력 및 분석 ã SAP Korea 2000 / 3 * HR * - 분류 - 도면/기술문서 - 자격/경력관리 - Time sheets (CATS) CSP : Complementary Software Partner - 정비계획 생산계획시 반영 CA QM - 측정장비 검교정 PP
SAP R/3 PM 구성요소 Technical Data Maintenance Processing Preventive Maintenance Project Management PM Information System ã SAP Korea 2000 / 4 • Functional Location 마스터 • 설비마스터 • BOM • Measuring Point • Networks of Tech. Objects • 고장분석 코드 • 작업요청 • 작업오더 • Task List(표준작업절차) • 보전전략 • 예방보전 계획 • Shutdown/Turn-around Project • 분석 및 Report
설비체계 (Functional Location) C 1 Clarification plant C 1 -M Mechanical cleaning C 1 -M 01 Sand trap C 1 -B Biological cleaning C 1 -M 02 Oil/fat trap C 1 -B 01 Pump plant C 1 -M 01 -1 C 1 -M 01 -2 C 1 -M 01 -3 C 1 -M 02 -1 C 1 -M 02 -2 C 1 -M 02 -3 Sand Fat Reservoir Ventilator dredger 공장전체 설비 Hierarchy 구성 • Process 기준 • 기술적 기준 • Location 기준 • 원가 관리 기준 특정 Level하부의 설비에 대한 분석 • 정비건수 • 정비요청 • Cost ã SAP Korea 2000 / 6 C 1 -B 02 Filtering station C 1 -B 01 -1 C 1 -B 01 -2 Pump 1 Pump 2 C 1 -B 02 -1 C 1 -B 02 -2 Filtering Ventilator cell C 1 -B 02 -1 A C 1 -B 02 -1 B C 1 -B 02 -2 A C 1 -B 02 -2 B C 1 -B 02 -2 C Filtrate Valve 1 Valve 2 Inlet level Outlet C 1 -B 02 -2 A/1 C 1 -B 02 -2 A/2 C 1 -B 02 -2 C/1 C 1 -B 02 -2 C/2 Valve 1 Valve 2
자산관리(AM) Interface Master Data Link & Synchronization • Equipment Master • Func. Location Master Asset Master Synchronization Rule 정의 (Field Mapping, 생성, 변경) 작업오더 정산 작업오더 발생 비용 ã SAP Korea 2000 / 12 자산가액 증가
Notification 구조 • 작업요청 시 파일첨부 Notification 날짜 / 시간 / 보고자 설명 Object: Functional location 설비 Assembly Material serial number 위치정보 Breakdown / 가용성 Notification Text items Activities Tasks ã SAP Korea 2000 / 16 고장부위 고장유형 고장원인 조치사항 실행 횟수 날짜 Task description
고장 Catalog • • 고장유형, 고장원인, 고장부위별 고장 Catalog를 사용자가 정의 고장 Catalog별 고장분석 및 고장 Report Catalog 유형 고장부위 고장원인 고장유형 조치 Activity Catalog 구조: 고장유형 Catalog Mechanical damage Code group Code ã SAP Korea 2000 / 17 예제: Code 010 020 030. . . Corrosion Broken glass Engine defect. . .
작업지시(PM Order) : Object List 1건의 작업오더에서 여러 개의 설비, Functional Location, 작업요청 처리 Order 901760 Object list 901760 M-1000 -N 001 M-1000 -N 002 Equipment or Functional locations or Notifications ã SAP Korea 2000 / 20
외주용역 처리방법 • 3가지 방법으로 외주용역 처리 지원 • 상근 외주 • 근접 협련업체 External company work center Control key PM 01 External service = " " Service = " " Capacity load 일괄계약 형식 Control key PM 02 Individual purchase order External service = X Service = " " 제공되는 용역에 대한 용역마스터 Control key PM 03 Service Master ã SAP Korea 2000 / 24 Required Available External service = X Service = X Purchase requisition Service items Free
작업오더 (오더정산) - 작업오더 처리시 발생비용 정산하여 실시간 원가 반영 (CO와 Integration) Receiver : Cost Center, Asset, Project, Order…. AM asset CO / PP / PM order Project Sender cost center Receiver cost center Credit Labor allocation Debit Labor Material External service Maintenance order Debit Labor Material External service ã SAP Korea 2000 / 29 Settlement Billed labor Billed material Billed external service
Refurbishment- Condition-Based Material Valuation 수리용 자재수리 (자재상태별 관리) Material -신규구매 상태 with valuation category C (condition-based valuation) -수리후 상태 -수리전 상태 Valuation type C 1 $ 3, 000 ã SAP Korea 2000 / 30 Valuation type C 2 $ 2, 500 Valuation type C 3 $ 200
Action Log Who changed what and when? 작업오더 Causes of damage Texts Address 작업요청 Purchasing data Malfunction data Sales data Technical objects Priorities Dates ã SAP Korea 2000 / 31 Damage Account assignment data
Document Flow All document types created for maintenance order can be displayed: 작업오더 ã SAP Korea 2000 / 32 - Notification - Completion confirmation - Goods movement - Purchase requisition - Purchase order
예방보전 유형 예방보전 시간주기 가동실적 주기 Condition-based 1999 30 40 50 60 20 10 70 80 Pressure Temperature Pressure Thickness ã SAP Korea 2000 / 34
예방보전 보전계획 • 대상 설비/설비리스트 • 보전전략 (작업주기: 시간주기, Performance) • 작업리스트 • Scheduling Parameter • 작업부서 Scheduling 보전계획 일정 Notification 작업오더 ã SAP Korea 2000 / 35 작업오더 • Scheduling Overview List Display, Graphical Display • 계획비용 Simulation 외주작업
단일주기 계획 1999 94 96 98 1997 2000 점검 s ar e 2 y 소화기 점검 I must perform the same inspections at regular intervals. ã SAP Korea 2000 / 37
전략계획 1 mon th 외부 육안검사 3 mon ths 내부 육안검사 1 year Check gear teeth for wear Which parts must be maintained at which intervals? ã SAP Korea 2000 / 38
작업표준 & 예방보전 전략 Time - factory calendar 작업표준 Operation 10 Operation 20 Operation 30 Operation 40 Operation 50 3 mon ths Operation 60 Operation 70 6 mon ths ã SAP Korea 2000 / 39
예지보전 (Condition-Based Maintenance) DCS/PCS/SCADA & R/3 Interface Fieldbus(DCS용 공장 Network) - 주요부위 측정값 전달 - 이상 신호 전달 사내 전산망 measuring devices & actuators DCS/PCS Interface S/W - CSP SAP R/3 -PM 모니터링 & 제어지시 measure actuate Equipment 작업이력 고장 및 원인 작업지시 자동발생 process and equipment condition Equipment CSP : Complementary Software Partner ã SAP Korea 2000 / 40 process and equipment condition
Certified DCS Integration Mettler-Toledo [Form. Weigh Formulation Software ®] ISA Industrieelektronik [ISA P Control] Yokugawa Electric [Link for SAP] Aspen Technology [ERP Connect] Envisionit Software [Visual. Flow] Digital Equipment [PDAS] Elsag Bailey [Symphony] OSI Software [PI] Siemens [SIMATIC PCS 7] Foxboro Eckardt [I/A Series] Sequencia [Enterprise Batch] Inenco [Mikon for R/3 PI-PCS] IBM Japan [IBM Production Connect Service] AUCOTEC Automatisierungs- und Computertechnik [AUCOPROVIS] Hewlett-Packard Analytical Products Group Europe [HP Enterprise Link] …. ã SAP Korea 2000 / 41
Project Based Maintenance PS • Scheduling & Resource Planning • Cost Planning & 비용집계 • 예산통제 WBS PM order 1 PM order 2 PM order 3 Op 10 Op 20 Op 30 PM l Single order cost planning and control l Resources planning l Scheduling ã SAP Korea 2000 / 43
Usage List S-15 o lled a t s In /01 n 03 - 설비에 대한 Usage History 관리 Dism antle /98 Usage list 03/01/ - 09/20/98 ã SAP Korea 2000 / 45 S-15 d on 09/2 0/98
Maintenance History Completed notifications Completed orders Object Damage description Work center Damage objects Downtimes Scheduling of work Activities Material usage Tasks Lists Costs by class ã SAP Korea 2000 / 46
Material Usage • • ã 자재 사용이력 예: 자재 100 -100 사용기간 : 1999/01/01 ~ 1999/12/31 SAP Korea 2000 / 48
Reporting Tools • List editing (Master, Notification, Order…) • Multi-level list editing • Plant Maintenance Information System (PMIS) - 표준 분석 - 사용자 정의 분석 - Early Warning • ABAP/Query • Report Painter • Custom ABAP reports • Download to external systems (MS Excel, Word, Text File …) ã SAP Korea 2000 / 49
도면/문서 관리-기능 기능 R/3 와 Integration Version 관리 도면/문서 구조 분류시스템 도면/문서검색 Vault(저장서버) 도면/문서마스터 R/3 Server 문서상태관리 도면/문서배포 Links to other SAP objects Material master Equipment Customer. . . . 설계변경 Workflow. . . 외부시스템과 Interface Workstation applications CAD systems via SAP-CAD interface Archive systems via SAP Archive. Link ã SAP Korea 2000 / 52
도면/문서 저장 서버 Secure Storage Archive Application server Check-In Check-Out Vault SAP database Frontend 공유(Mount) File server ã SAP Korea 2000 / 53
Direct File Viewer Integration • SAGUI(Client)에 도면 Viewer 내장 (EAI) ã • Office Program Plug-In • Viewing 2 D, 3 D CAD Files • Image Files • Red. Lining, Mark. Up SAP Korea 2000 / 54
my. SAP. com Workplace Web Browser로 R/3 모든 기능 사용 Launch. Pad Mini. Apps (사용자메뉴) 사용자가 정의한 정보를 보여줌 Personalized, role-specific navigation <Example> Drag & Relate ã SAP Korea 2000 / 57 • Mail • 현재 작업요청 건수 • 작업오더 처리 상황 • Back. Order 현황 • . . .
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