SAP Plant Maintenance Training Course

Participants can define master-data structures that support planning, history and reporting.

• Maintenance planning plants, planner groups and work centres defined
• Functional locations structured by system, location and maintainable boundaries
• Equipment records built with manufacturer data, warranties and classification
• Object types selected for serialised assets and repairable spares
• Bills of materials assigned to equipment and functional locations
• Class characteristics standardise asset attributes and reporting filters

Participants can create controlled maintenance requests and capture usable failure information.

• Notification types distinguish breakdown, malfunction, activity and service requests
• Catalog profiles code damage, causes, activities and object parts
• Priority matrices translate business impact into response and completion targets
• Malfunction start and finish times produce downtime records
• Long-text standards capture symptom, condition and technical findings
• Notification status controls handover, approval and order creation

Participants can create maintenance orders with controlled scope, status and technical context.

• Order types govern planning, execution, settlement and approval routes
• Control keys determine internal labour, external services and confirmation requirements
• Operations, suboperations and relationships represent executable job sequences
• Standard text keys create repeatable scopes, methods and acceptance criteria
• Maintenance order statuses prevent premature release, closure and settlement
• Reference objects carry history, costs and technical context into orders

Participants can build reusable job plans and derive planned maintenance costs.

• Task lists capture operations, components, tools and standard labour values
• General task lists support reusable methods across similar asset classes
• Equipment task lists preserve asset-specific work instructions and history
• Functional-location task lists organise system-level inspection and servicing work
• Work centres provide capacity, activity types and scheduling formulas
• Planned costs derive from labour, materials, services and overheads

Participants can control material and service requirements within maintenance orders.

• BOM reservations identify planned components before order release
• Material availability checks expose shortages and procurement lead-time risks
• External operations create purchase requisitions, service entry and invoice controls
• Service specifications define scope, quantities, acceptance and commercial limits
• Repairable spares processes track removal, refurbishment and return-to-stock
• Goods issues and returns preserve order-level material cost traceability

Participants can schedule maintenance work against capacity, priority and operating constraints.

• Order dates calculated through operation durations, relationships and floats
• Capacity requirements compared against work-centre availability and shift calendars
• Dispatching rules sequence ready work by priority, dates and constraints
• Maintenance backlog segmented by age, priority, craft and asset criticality
• Weekly schedules freeze committed work and protect emergency capacity
• Schedule compliance distinguishes planned, scheduled, started and completed work

Participants can control order release, execution confirmation, technical completion and closure.

• Order release confirms permits, materials, capacity and technical readiness
• Mobile execution captures confirmations, measurements, photos and failure codes
• Actual labour and material postings compare execution against plan
• Partial confirmations record progress, remaining work and revised completion dates
• Technical completion controls outstanding reservations, purchasing and follow-up actions
• Order closure validates history, costs and settlement readiness

Participants can design time-based maintenance plans using cycles, packages and scheduling parameters.

• Time-based strategies define cycle sets, packages and call horizons
• Single-cycle plans schedule recurring inspections, lubrication and statutory tasks
• Strategy plans bundle short, medium and long interval packages
• Maintenance items connect task lists to equipment or functional locations
• Scheduling parameters control call objects, tolerances and automatic release
• Maintenance plan completion updates due dates using confirmation data

Participants can use measurement data to trigger and schedule condition-based maintenance work.

• Measuring points define counters, readings, limits and measurement positions
• Measurement documents record meter readings, condition values and timestamps
• Counter-based plans generate calls from operating hours, distance or cycles
• Performance-based scheduling uses estimated and actual counter readings
• Threshold values trigger notifications from adverse condition measurements
• Data quality checks identify implausible readings and missing measurements

Participants can connect maintenance orders with isolation, permit and return-to-service controls.

• Work clearance management links maintenance orders to isolation and permits
• Permit-to-work steps coordinate operations, safety roles and release conditions
• Lockout-tagout requirements documented through operational and maintenance procedures
• Safety measures assign personal protective equipment and hazard controls
• Clearance statuses prevent work before isolation verification and approval
• Return-to-service checks confirm reinstatement, testing and operational handover

Participants can analyse maintenance cost and apply order-level financial controls.

• Cost elements separate labour, materials, services and overhead allocations
• Planned-versus-actual analysis identifies estimate errors and execution variance
• Settlement rules transfer maintenance costs to cost centres or assets
• Order budgets set tolerance limits and approval escalation points
• Activity types price internal labour through controlling rate structures
• Cost reports support monthly accruals, forecasts and variance commentary

Participants can define maintenance KPIs and interpret performance from SAP PM data.

• Backlog weeks calculated from labour demand and available craft capacity
• Schedule compliance tracks work completed within committed weekly windows
• Planned maintenance percentage separates proactive orders from reactive work
• Mean time between failures uses operating time and functional failures
• Mean time to repair combines repair durations and repair counts
• Dashboard definitions reconcile SAP order data with management KPI rules

Participants can identify recurring asset losses and investigate their underlying causes.

• Failure codes standardise problem, damage, cause and remedy analysis
• ISO 14224 taxonomy aligns equipment classes, failure modes and data fields
• Pareto charts rank repeat failures by frequency, downtime and cost
• Five Whys tests causal chains beyond immediate repair observations
• Cause-and-effect diagrams organise mechanical, electrical, process and human factors
• Bad-actor registers prioritise assets by recurring loss and intervention value

Participants can select maintenance strategies using criticality, FMEA and RCM decision logic.

• Asset criticality matrices score safety, environmental, production and cost consequences
• FMEA identifies failure modes, effects, controls and risk priorities
• RCM decision logic selects condition-based, scheduled, redesign or run-to-failure tasks
• Weibull analysis distinguishes infant mortality, random failures and wear-out patterns
• Maintenance strategies revised using failure evidence, task effectiveness and economics
• Reliability improvement proposals define owner, action, benefit and verification measure

Participants can explain and manage SAP PM integration points affecting maintenance delivery.

• MM integration converts component demand into reservations and purchase requisitions
• FI and CO integration posts maintenance costs and settlement documents
• Quality notifications connect inspection findings with corrective maintenance orders
• Project System links shutdown work packages to project structures
• Document Management System attaches drawings, procedures and certificates
• GIS and linear asset references locate work on networked infrastructure

Participants can plan and control maintenance work executed during planned outages.

• Shutdown scopes assemble work lists, resources, materials and contractor requirements
• Network logic sequences outage tasks using dependencies, durations and milestones
• Critical-path analysis identifies schedule drivers and float consumption
• Turnaround readiness reviews test drawings, spares, permits and work packs
• Daily control rooms manage progress, constraints, changes and recovery actions
• Post-outage reviews capture lessons, cost variance and scope growth

Participants can establish governance controls for maintenance data quality and accountability.

• Master-data ownership assigns creation, change approval and periodic review responsibilities
• Data standards define naming, coding, mandatory fields and validation rules
• Duplicate detection resolves redundant equipment, materials and functional locations
• Migration mapping reconciles legacy fields with SAP object structures
• Role-based access separates requester, planner, supervisor and cost approval duties
• Audit extracts demonstrate status history, approvals and master-data changes

Participants can define process ownership, governance routines and improvement priorities for SAP PM.

• Maintenance process maps define handoffs from request through performance review
• RACI matrices assign accountable roles for planning, execution and closeout
• Planner-scheduler routines establish weekly gates, backlog reviews and escalation
• Standard job plans reduce planning variability and improve estimate quality
• Data review cadences convert KPI exceptions into corrective actions
• Implementation roadmaps sequence governance, master data, process and reporting changes

Participants can build, review and present a complete SAP PM maintenance and asset reliability work pack.

• Asset register excerpt establishes functional locations, equipment and criticality rankings
• Notification analysis identifies failure patterns, priorities and corrective requirements
• Maintenance plan combines task lists, cycles, packages and measurement triggers
• Order work pack specifies operations, materials, services, costs and safety controls
• Weekly schedule balances backlog, capacity, permits and material availability
• Reliability proposal applies FMEA, KPIs and a quantified action register
• Peer review tests data quality, process controls and presentation rationale