High Tech: Preventive Maintenance with Counters

This Business Scenario Map shows a coherent, cross-industry process for monitoring, calibrating, and maintaining equipment. Condition-based maintenance with calibration inspections is a coherent, cross-industry process for monitoring, calibrating, and maintaining equipment. It shows how maintenance engineers, quality inspectors, and asset operators (users) can benefit from systematic quality inspections of equipment - from the first use of an equipment until its replacement.

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Value Potentials	Business Benefits
Up to 40% decreased overall down-time due to streamlined inspections*	Planned calibrations integrated in production process
	Easy work planning by worklists
	Detection of hidden non-conformities by quality inspections
	Tracking, monitoring, and evaluating using usage lists, results history, trend analysis, and notifications
Up to 90% prevention of malfunctions*	Determining optimum time for repair or replacement
	Streamlined scheduling by condition-based modification of calibration intervals
Up to 100% avoidance of inappropriate equipment*	Automatic update of equipment status

Quality Inspector

Maintenance Engineer

Asset Operator

Confirm maintenance order

Record results

Carry out calibration inspection according to worklist

Complete order

Make usage decision including follow-up actions

Plan and schedule calibration

Monitor and evaluate

Use high-quality equipment

Collect reliable info. on asset availability & performance

Plan work according to scheduled calibration

Source:

* Discussions with Customers

**Gaither, Norman., Production and Operations Management, Eighth Edition, 1999, pg 750

The value potentials shown in this table have been reported by selected SAP customers or independent third parties as referenced herein. However, there is no guarantee that such value potentials can be realized in any particular customer-specific business processes, and SAP does not make any representations and disclaims any liability as to the appropriateness of the referenced value potentials for any specific customer situation.
©SAP AG 2008

Business Benefits	Value Potentials
Fast and reliable documentation with notifications and subsequent release of maintenance order, if required	Up to 60% accelerated correction process*
Documented equipment quality by notifications and measurement documents linked to the equipment
Reliability through quality inspections with clearly defined inspection characteristics	Up to 100% improvement in assessment of equipment condition*
Decrease in maintenance man-hours	up to 60%**
Decrease in equipment breakdown	by up to 40%**


High Tech: Preventive Maintenance with Counters A calibration inspection is a systematic examination used to determine whether or not a piece of equipment meets previously specified requirements. It combines features of the quality management and asset life-cycle management areas within SAP PLM. The map illustrates the benefits of condition-based maintenance through calibration planning and processing. The solution combines features of Asset-Life Cycle Management and Quality Management within SAP PLM. After a maintenance plan for a specific (list of) equipment has been set up, scheduled, and released due to a maintenance call, an inspection lot is created automatically. It allows the quality inspector to record inspection results and check whether these match the given calibration criteria. After valuating each piece of equipment, the maintenance engineer can make the usage decision for the inspection lot. If necessary, follow-up actions such as updating the equipment status ("operational" vs. "not operational"), reducing or extending calibration intervals according to the condition of the equipment, or creating measurement documents (which document the obtained inspection results), can be triggered automatically. This solution also allows determination of the optimum time for repair or replacement (by displaying a trend analysis), and condition-based scheduling of inspections (by setting a modification cycle factor). For evaluations of equipment, it also provides a usage list and a results history. This dynamic process allows you to streamline the maintenance schedule according to your needs.