Achieve Increased Efficiency through the Integration of Maintenance and Production

  • by Adolfo Menéndez Fernández, Application Architecture Manager, Repsol
  • April 30, 2009
Learn the steps to build the integration between maintenance activities and production planning/detailed scheduling in SAP Advanced Planning & Optimization. See how integration between these areas and departments creates more visibility over common processes to help alert planners to possible downtimes and lack of materials.
Key Concept
Many companies rely on SAP Production Planning (PP) for the production planning process while they use SAP Plant Maintenance (PM) for maintenance activities. With PP, companies can manage the manufacturing processes from planning to execution, integrating those processes with other areas such as sales and distribution and purchasing and controlling. PM covers a company’s maintenance requirements through activities such as inspection and preventive and corrective maintenance.

With the release of SAP SCM 4.1 in 2005, SAP delivered a new and interesting functionality: the integration of maintenance orders in SAP SCM. Before this release, production planners using SAP Advanced Planning & Optimization (APO) were not able to get the information related to maintenance activities in the system. Now you can easily display maintenance orders in SAP APO. That means you can coordinate both production and maintenance areas, and manage products used by maintenance personnel and consumed by production operations.

For instance, often shared materials used in maintenance orders were not reflected in the replenishment plan. Materials not reflected in the replenishment plan can cause big problems for planners. If production starts, the plant won’t have the required components to finish the item, and this could cause a halt in the work center. For example, suppose the maintenance team has consumed a box of screws needed to complete a product, but this is not reflected in the replenishment plan. The production line has to be stopped and kept waiting until new screws arrive. A plan reflecting shared materials could have given the planner time to re-plan the production for those days, such as moving production to an alternative resource, anticipating the production orders, or subcontracting the operation. Instead, time is lost.

My integrated scenario involves three areas: Production Planning (PP) and Plant Maintenance (PM) in SAP ERP, as well as SAP APO, which contains the production planning and scheduling tools. I will explain in the following steps how to integrate PP and PM as well as cover the main points to consider when integrating the maintenance and production activities with SAP SCM, including some explanations about settings of PP and PM that are not commonly used.

Adolfo Menéndez Fernández

Adolfo Menéndez Fernández is the application architecture manager at Repsol in Madrid. Previously, he worked at SAP Consulting Spain as the logistics consulting manager. He studied at the University of Oviedo, where he earned an electronic engineering degree. He is a certified SAP consultant in supply and demand planning (SNP and DP), order fulfillment (Global Available-to-Promise), production planning and detailed scheduling (PP/DS), as well as procurement and materials management (MM). Adolfo has more than 10 years of SAP implementation experience in the consumer product goods, pharmaceutical, automotive, furniture, textile, chemical, oil & gas, and steel industries using SAP ERP logistic modules (including PP, MM, and sales and distribution [SD]) as well as SAP SCM (DP, SNP, and PP/DS). He is APICS certified in Production and Inventory Management (CPIM).

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