Introducing Corrective Maintenance (BH1)

Objectives
After completing this lesson, you will be able to:

After completing this lesson, you will be able to:

  • Explain the corrective maintenance process
  • Review process steps for corrective maintenance (BH1)

Corrective Maintenance Process

Understanding the Corrective Maintenance Process

The corrective maintenance repair process goes through several planning stages, such as preliminary costing, work scheduling, material provision, resource planning, and permits. You can also react immediately to issues that may lead to the shutdown of production facilities.

If required, a Maintenance Technician can create the required maintenance work orders and shop papers with a minimum of entries in the shortest possible time. The notification usually refers to a technical object and contains a description of the malfunction or the requirements. In addition, data can be entered in a notification to build up the history (for example, damage, causes, and so on). Based on a notification, maintenance tasks can be planned. This leads frequently, but not necessarily, to the creation of a maintenance order

A maintenance order is planned based on a notification. Typically, planning activities comprise the creation of order operations including planned work efforts and the reservation of relevant material or spare parts. You also plan for the materials (stock and non-stock) required to execute a task for each operation in the maintenance order. The materials can be Bills of Materials (BOMs) components for the reference object or freely assigned materials.

The cost can be calculated for personnel and materials at any phase in a maintenance order. Cost analysis based on the costs are (automatically) calculated in the maintenance order. The costs are calculated by default at header level of the maintenance order (for planned as well as for actual costs).

A Maintenance Planner ensures that the orders are processed in time. The Maintenance Planner must ensure that the materials are available, shop papers are printed, and orders are released for processing.

Before a maintenance task can be technically completed, the working times are entered in the time confirmation. After confirming a maintenance task, the order and notification are then completed. The completion of an order consists of two steps: technical completion and business completion. So if no more task is left from a maintenance perspective, then a maintenance order is set to technically completed.

The data in the settlement rule provides information on which account assignment object the costs are to be settled. The account assignment object is proposed from the master record for the reference object and can be changed when the first settlement rule is maintained for the order

Steps in Corrective Maintenance

The corrective maintenance process involves the following steps:

  1. Malfunctions and other requirements are recorded in a notification.
  2. Orders are created and planned based on the reported requirements. Planning encompasses the steps to be taken and the material required.
  3. The order runs through different checks (such as material availability checks and capacity planning) which are important for the release of the order. The system checks whether permits need to be approved, safety plans are required and if the work clearance requirements for certain areas are fulfilled. If no problems arise during these checks, the order is put in process. The shop papers are usually printed at this point.
  4. The order is executed. The required material for the order is withdrawn. This includes material that has not been planned, and therefore not reserved, by the order.
  5. Time confirmations and technical confirmations are entered in the system.
  6. The order is set to technically complete. The settlement of the order by Controlling (CO) can be performed before or after the technical completion of the order. Finally, the maintenance order is set to business complete. This step is executed by the Controlling department.

Corrective Maintenance (BH1)

Overview – Corrective Maintenance (BH1)

The scope item Corrective Maintenance (BH1) allows you to perform the corrective maintenance of technical objects when a breakdown or failure occurs. The plant maintenance component provides a comprehensive notification and order system to facilitate this process. You process a repair using several planning stages, such as preliminary costing, work scheduling, material provision, resource planning, and permits. You also react immediately to issues that may lead to the shutdown of production facilities. When this is necessary, as a Maintenance Technician, you create the required maintenance work orders and shop papers with a minimum of entries in the shortest possible time.

Benefits

  • Support processing of maintenance operations with internal resources.

  • Increase transparency of costs and time spent on individual assets for maintenance purposes.

  • Simplify actual order cost tracking and assignment of costs to settlement receiver for greater transparency and cost controlling.

  • Enable recording of working times on the cost objects for effort tracking.

  • Plan stock and non-stock materials and services for repair.

Applicable Process Steps

The following table lists the SAP Fiori apps and business roles that are used in the Corrective Maintenance (BH1) process steps:

Process StepBusiness RoleTransaction/App

Request Maintenance

Notification is created in multiple ways. This process step shows you how to use Request Maintenance by employee.

Employee

Request Maintenance (F1511)

Monitor Maintenance Requests

The employee can check all existing notifications. This process step shows you how to check the list of existing notifications.

Employee

Monitor Maintenance Requests (F1511)

Change Maintenance Request into Malfunction Report

A malfunction report describes a malfunction on a maintenance object that may impair object performance. The malfunction report states that a technical system is not functioning correctly or working as well as it should (or not working at all).

Notification type can be adjusted according to the configuration setting. This process step shows how the Maintenance Planner can change maintenance notification type from maintenance request into a malfunction report.

Maintenance Planner

Find Maintenance Notification (F2071)

Create Maintenance Notification (Optional)

Corrective

Maintenance Technician

Create Maintenance Notification

Create Maintenance Order

This process step shows you how to create maintenance order.

Order processing helps you to plan maintenance tasks in greater detail: for example, those tasks from a malfunction report. You decide whether the tasks are to be performed and what components (materials) you need for them.

Furthermore, the maintenance order is used to collect all costs for a maintenance task and to debit the cost center that incurred the costs by using the settlement functions in the CO module (Controlling).

Maintenance Planner

Manage Order and Notifications in Information Center (W0019)

Release Maintenance Order

The maintenance order is used to collect all costs for a maintenance task and to debit the cost center that incurred the costs by using the settlement functions in the CO module (Controlling). This process step shows you how to release maintenance order.

Maintenance Planner

Manage Order and Notifications in Information Center (W0019)

Convert Purchase Requisitions to Purchase Orders

This process step shows you how to assign purchase requisitions to a source of supply and to convert assigned source purchase requisitions to purchase orders.

Purchaser

Manage Purchase Requisitions (F1048)

Post Goods Receipt for Purchase Orders

This process step shows you how to post the goods receipt for the purchase order.

Warehouse Clerk

Post Goods Movement (MIGO)

Maintenance Service Entry Sheet

In this activity, you report the performed services in the service entry sheet.

Purchaser

Manage Service Entry Sheets - Lean Services (F2027)

Approve Service Entry Sheet with Flexible Work flow

In this activity, the service entry sheet is approved by the company. When this is done, the vendor can send an invoice for the approved amount to the service provider. These flexible workflows are configured in the Manage Workflows for Service Entry Sheets app. The ordered amount will be converted using system exchange rate to the workflow currency. It will then be compared with workflow condition. If the user does not have My Inbox app, you must assign the following business catalogs to the business role of the user:

  • SAP_CA_BC_MYINBOX_PC

  • SAP_MM_BC_SES_WIAPPROVE_PC

This is necessary to enable the user to process incoming approval requests related to the workflow for the service entry sheet.

Project Manager - Commercial Services

My Inbox

Create Supplier Invoice with PO/GR Relation

This process step shows you how to create the invoice with reference to the purchase order.

Accounts Payable Accountant

Create Supplier Invoice - Advanced (MIRO)

Release Supplier Invoice

This process step shows you how to release a blocked supplier invoice.

Accounts Payable Accountant

Supplier Invoices List (F1060A)

Print Job Card

After the maintenance order is released, the maintenance technician can print the job card. This process step shows you how to print job card.

Maintenance Technician

Display Job List (W0016)

Confirm Maintenance Order

After finishing the corrective maintenance, you must confirm the order to record the real work time and the spare parts consumption. The data is used for follow-up cost evaluation. This process step shows you how to confirm maintenance order.

Maintenance Technician

Confirm Jobs (W0020)

Confirmed Unplanned Maintenance

After event recording or confirmation of unplanned maintenance, the occurrence of an event requires quick and immediate intervention from the maintenance technician. In such an emergency, the maintenance technician performs the required maintenance activity to restore the condition of the equipment. The maintenance technician identifies an issue with the equipment, immediately fixes the issue, and reports the time spent and the material consumed. Often, the technician may not be able to identify the equipment numbe, and must search the hierarchy of the functional location. This process step shows you how to confirm unplaned maintenance.

Confirm Jobs (W0020)

Confirm Jobs (W0020)

Show Costs on Maintenance Order

This process step shows you how to display the planned and actual costs here.

Maintenance Planner

Manage Order and Notifications in Information Center (W0019)

Technically Complete Maintenance Order

The maintenance notification is completed and the maintenance order is technically completed after the required maintenance work is done.

The technical completion reduces all the purchase requisitions, open reservations, and capacities still outstanding for the maintenance order.

Nevertheless, the order can still continue to receive costs: for example, through invoice receipts for delivered and used materials. However, it is blocked for all changes in the processing.

The order settlement transfers the costs incurred that were temporarily collected for the maintenance order, to the recipient. For example, to the cost center for the maintained object. This process step shows you how to technically complete maintenance order.

Maintenance Planner

Manage Order and Notifications in Information Center (W0019)

How to Monitor Maintenance requests (BH1)

How to Technically Complete Maintenance Orders (BH1)

How to Release a Corrective Maintenance Order (BH1)

How to Create a Goods Receipt (BH1)

How to Convert a Purchase Requisition to a Purchase Order (BH1)

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