SAP Plant Maintenance (TOPO) makes it possible to forecast and effectively plan the maintenance and repairs of equipment, control the execution of repairs, manage the cost of procurement of materials and spare parts, automatically create analytical and reference reports, to analyze the effectiveness of resource usage.
SAP PM functionality
Unified Regulatory Information Management System
- Hierarchical maintenance of the organizational structure of each production site and repair facilities;
- Accounting and detailing of all repair facilities, production, and auxiliary equipment
- Registration of all technical places for maintenance and repair
- Maintaining spare parts base
- Maintaining the history of repairs and operation of the enterprise’s facilities
Planning
- Scheduling maintenance activities at each repair facility
- Maintenance of process flow charts for each M&R facility
- Maintenance of equipment specifications
- Preparation of repair procedures and plans
- Generation of orders for scheduled repairs
- Accounting for emergency repairs and monitoring of work performance
Accounting for emergency repairs and monitoring of work performance
- Generation of messages about emergency repair and stoppage of production line / power facility
- Generation of orders for emergency repairs
- Daily (every shift) orders to the engineering service for maintenance and repair of equipment
- Monitoring of work performance under work orders
Reporting
- Emergency downtime report
- Report on repairs performed
- Repair plans report
- Equipment status report
- Report on the availability of spare parts and materials in warehouses
Monitoring of production line operation in real-time mode
- Real-time tracking of the status of production line indicators
- Data input at the location of the repair facility at the time of the work
- Reporting on task completion
- Performance monitoring
Accounting for the quantity of spare parts and ordering of spare parts by the supply service
- Accounting and analysis of materials consumption and time consumption by types of M&R
- Preparation of repair schedules and budgets based on repair strategies, material and time consumption standards
- Preparation of the production program of repair units and the plan for the purchase of materials
Benefits
- Increase fault tolerance and maximize equipment life
- Reduction of operating costs and unscheduled shutdowns
- Increase production efficiency by reducing product losses caused by equipment shutdowns or equipment malfunctions
- Transparency of repair work
- Reduced maintenance and repair costs
- Improved planning and availability of materials and spare parts
- Reducing transaction costs by optimizing procurement procedures from suppliers of materials and spare parts
- Less energy consumption
- Effective planning and minimization of downtime of repair personnel
- Personnel performance tracking
- Strict observance of labor protection, reduction of accidents and elimination of violations of environmental requirements
- Seamless integration with the Customer’s ERP system and related enterprise processes
