This article will discuss about complete transaction journey to track work order’s material, labor and cost on SAP PM from scheduling stages until realization then followed up by consolidation report.
Plant Maintenance Control Key
Work Order Control Key
Control key in context of SAP PM (Plant maintenance) is a value to define how the maintenance order is going to be processed.
genrally there are three types of PM control key
- PM01 is used for internal operation. Both of the material and labor will be came from internal (in-houses) organization resources through internal work center.
- PM02 or also known as outsourcing operation. Both of the material and labor will be part of vendor responsibility. vendor will provide the material and labor.
- PM03 is subset of PM02 process. Material or spareparts will be provided by internal organization, however vendor will execute the maintenace. They provide the labor
Control Key Implementation
Phase: WO Scheduling
| No | Type | Control Key | Labor | Material |
|---|---|---|---|---|
| 1 | Internal Operation | PM01 | Inhouse (IH) | Inhouse (IH) |
| 2 | Fully Outsource | PM02 | Outhouse (OH) | Outhouse (OH) |
| 3 | Labor Outsource | PM03 | Outhouse (OH) | Inhouse (IH) |
PM02 and PM03 require additional SAP MM/FICO to be configured such as : services master to record the external services(labor) pricing detail , Valuation price or category for external material price
Rate Computation
internal and external maintenance operation has different way to compute the rate. Internal operation will solely rely on the activity type while the external operation need to involve combiation of service master, valuation price & category, OA and PIR as shown below
Rate Sources
Phase: WO Scheduling
| No | Type | Control Key | Material | Labor | Material Order | Services Order |
|---|---|---|---|---|---|---|
| 1 | Internal Operation | PM01 | Valuation Price & Category | Activity Type | none as it is internal | as it is internal |
| 2 | Fully Outsource | PM02 | OA/PIR | OA/PIR | PR -> PO (if material source is VMI): VMI->S Loc -> PR -> PO |
PR -> PO |
| 3 | Labor Outsource | PM03 | Valuation Price & Category | OA/PIR | none as it is internal | PR -> PO |
*PIR = Purchasing info record *OA = Outline Agreement
Valuation price & Category
- Standard price (S)—for internal warehouse
- Moving average price (V)—for externally purchased but still internal stock
Cost Collector
SAP doesnt have rigid collector for specific control key. Each control key can be assigned to any cost collector
- Cost Center: daily activities/operation which aimed to perserve the assets condition but not prolong the asset age.
- WBS: project based activity (eg: for turn around/TA project)
- AUC(Asset under construction): usually high cost activities to prolong the asset age (eg: for turn around/TA project)
cost center is OPEX to track ongoing operational cost while WBS and AUC is CAPEX (capital expenditure)
Realization
One of the key performance indicator (KPI) of reliability and maintenance departement is planned vs actual resource consumption deviation.
if the actual resource utilized is way more than the planned allocation, an evaluation and improvement is needed as this could lead into bigger problem especially if the budget is affected.
below is the process of capturing actual material,labor and cost consumption
Phase: Just before execution
to record actual usage
| No | entity | T-Code |
|---|---|---|
| 1 | Stock Material | GI(Good Issue) from warehouse to WO |
| 2 | Non Stock Material | Good Receipt to WO |
Phase: After TECO (technically complete)
to record actual usage
| No | entity | T-Code |
|---|---|---|
| 1 | Internal labor | Time Confirmation |
| 2 | External labor | SES (Services Entry Sheet) |
Reconcilliation report
Unfortunately SAP PM doesnt built in feature to create a report which show planned vs actual resources consumption in single view.
It has to be custom developed.
in order to be able to track actual sparepart and man hour consumption, its important to understand how SAP record the planned sparepart and man hours in form of bill of material, work center and work order.
Pre-requisites
Before the tracking of labor & material can be done, all the neccesary master data need to be properly added on SAP PM.
Equipment’s Bill of Material (BOM)
in SAP, bill of material is a structure of a product which is formed from one or many component regardless whether it can be stored on storage or not.
these components are tied to one specific product and each of the prouduct can have different bill of material. Meaning different component structure which compose the product.
— both of equipment and functional location (technical object) has an associated BOM.
However, bill of material on context of SAP PM (plant maintenance) can mean two things as shown in following explanation.
Asset Structure
in case a specific damage recording on the physical asset is needed, the component of those physical asset can be structurized as bill of material on SAP PM.
for example, a pump has three main component parts such as : motor, shaft and control electronic.
These structure can be registered on SAP PM. So, when a failure happen on one or more specific component of the pump, it can be assigned specifically on that bill of material.
