sap-pm

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name: sap-pm description: > This skill handles SAP PM (Plant Maintenance / 설비보전) including Equipment Master (IE01/IE02/IE03), Functional Location (IL01/IL02/IL03), Maintenance Notifications (IW21/IW22/IW23), Maintenance Orders (IW31/IW32/IW33), Preventive Maintenance (IP01/IP10/IP30), Task Lists (IA01/IA05), Maintenance Planning, and Plant Maintenance Reporting (IW28/IW29/IW38/IW39). Use when user mentions PM, 설비보전, 설비관리, equipment, 설비, maintenance order, 보전오더, 고장, breakdown, 고장코드, preventive maintenance, 예방보전, functional location, 기능위치, MTBF, MTTR, 점검, 정비, serial number, 시리얼, refurbishment, 재생정비, maintenance planning, maintenance strategy, 정비전략, equipment history, 설비이력, preventive tasks, 예방점검. allowed-tools: Read, Grep

1. Environment Intake Checklist

Before answering PM questions, collect:

• SAP Release: ECC 6.0 (which EhP?) or S/4HANA (which release year?)
• Deployment model: On-premise / RISE / Cloud Public Edition
• PM Organization: Planning Plant, Maintenance Plant, Maintenance Coordination Plant
• Industry sector: Manufacturing (automotive, chemicals, electronics), energy, pharma, food & beverage
• Equipment strategy: Single-level (equipment only) vs. two-level (equipment + functional locations)
• Maintenance type focus: Breakdown, preventive, predictive, contract, or combination?
• Integration requirements: MES, predictive maintenance (PAI), mobile (SAP Asset Manager), analytics

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2. Equipment Master Data (IE01/IE02/IE03)

Equipment Creation (IE01)

Key T-codes & Menu Path

• IE01: Create Equipment (SPRO → Plant Maintenance → Master Data → Equipment → Create)
• IE02: Change Equipment
• IE03: Display Equipment
• IE10: Create Fleet (for mass equipment with identical configuration)

Critical Fields (EQUI Table)

Field	Meaning	Mandatory	Notes
EQUNR	Equipment number	Y	Unique 18-char ID; can be internal/external assigned
EQKTX	Equipment description	Y	40 chars; recommend English + Korean
EQART	Equipment category	Y	PUMPE (pump), MOTOR (motor), KOMPR (compressor) etc.
MATNR	Material master	N	Links to inventory; if serial-tracked material, serializes equipment
SERGE	Serial number	N	Hardware serial from nameplate; used in warranty tracking
HEQUI	Higher-level equipment	N	Parent equipment (e.g. pump is part of production line)
ILOAN	Functional location	Y	Must exist in IFLO before assignment
MANDT	Company code	Y	Set at creation; cannot change
WERKS	Plant	Y	Maintenance-executing plant
KMFID	Manufacturer	N	Free-text; recommend SAP vendor master LIFNR
GEWICHT	Weight	N	For spare parts estimation
INBDT	Startup date	N	Important for MTBF calculation period

Equipment Classification

Table KLAH (classification header) + KLASP (assignment):

• Class type: EQUIPMENT, ZEQUIP (custom)
• Characteristics: Model, Manufacturer, Voltage, Capacity, Brand
• Used for: spare parts list filtering, maintenance strategy assignment, reporting

Serial Number Management

• Equipment must link to material master (EQUI.MATNR)
• Material → Accounting 1 view → Valuation Class + Serial Number Profile (MMSL)
• Serial Number Profile (MMSL): defines when system forces serial entry during GR, GI, MIGO
• Equipment History (EQUZ): automatic log of changes (creation, equipment change, tag changes)

Equipment Deletion

• Equipment cannot be deleted if it has maintenance history (QMEL, AUFK exist)
• Workaround: Flag EQUI-LOEKZ (deletion flag) = X → equipment hidden in selection, kept for history

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3. Functional Location Master Data (IL01/IL02/IL03)

Hierarchical structure — represents plant's physical/logical organization

Functional Location Creation (IL01)

Key T-codes

• IL01: Create Functional Location (SPRO → Plant Maintenance → Master Data → Technical Objects → Functional Location)
• IL02: Change Functional Location
• IL03: Display Functional Location

Hierarchy Example (Two-Level Strategy)

Production Line A (ZFUNCLOC-PRODLINE-A)
├─ Section 1 (ZFUNCLOC-PRODLINE-A-SEC1)
│  ├─ Equipment: Motor, Pump, Control Panel
└─ Section 2 (ZFUNCLOC-PRODLINE-A-SEC2)
   ├─ Equipment: Conveyor, Sensor

Critical Fields (IFLO + IFLOT Tables)

Field	Table	Meaning	Notes
TPLNR	IFLO	Functional location ID	40-char hierarchical, e.g., PROD-001-002
TXTMI	IFLOT	Description (multilingual)	Store in DE, EN, KO
FLTYP	IFLO	Functional location type	e.g., PUMPING_STATION, MOTOR_ROOM
GEWRK	IFLO	Responsible work center (PM team)	Links to CR01 work center
HFLOC	IFLO	Higher-level functional location	Parent node
STRNO	IFLO	Building/hall number	Organizational reference
MANDT	IFLO	Company code	Assigned at creation

Account Assignment

• Cost center (KOSTL): for cost tracking of maintenance labor + materials
• Internal order (AUFNR): for project-based maintenance (e.g., annual overhaul)
• Profit center: for P&L attribution
• WBS element: for capital project maintenance

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4. Maintenance Notification (IW21/IW22/IW23)

Entry point for all maintenance requests — whether breakdown or planned

Notification Types (QMNUM Table)

Notification Type	ID	Trigger	Example Use Case
Malfunction (고장)	M1	Breakdown reported by operator	"Motor stopped working"
Maintenance request	M2	Preventive or user-initiated task	"Annual pump inspection needed"
Activity report (업무보고)	M3	Post-maintenance completion record	"Replaced bearings on motor"
Calibration notification	M4	Instrument calibration schedule	"Pressure gauge needs recalibration"

Key T-codes

T-code	Description
IW21	Create notification
IW22	Change notification
IW23	Display notification
IW24	List of notifications (selection)
IW28	Notification listing (reporting)
IW29	Notification analysis (OLAP)

Critical Fields (QMEL + QMIH Tables)

Field	Table	Meaning	Max Length
QMNUM	QMEL	Notification number	12 digits (internal/external assigned)
QMTXT	QMEL	Short description	40 chars
LTXT	QMEL	Long text	2500 chars (ALV memo)
EQUNR	QMEL	Equipment or...	18 chars
TPLNR	QMEL	Functional location	40 chars (either EQUNR or TPLNR required)
SCHAD	QMEL	Damage/fault code	4 chars; must exist in custom table (e.g., ZMAINTCODES)
URSACHE	QMIH	Root cause code	4 chars; ABAP table maintained via SPRO
AKTIVITAET	QMIH	Activity code (work type)	4 chars; e.g., REPAIR, INSPECT, REPLACE
ANLDAT	QMEL	Notification creation date	Auto-filled
MERDAT	QMEL	Reported date/time	User-entered (when problem was discovered)
PRIO	QMEL	Priority (1=urgent, 4=low)	Links to SLA
ARBPL	QMEL	Assigned work center	CR01 resource pool
AUART	QMIH	Associated order type	e.g., PM01, PM02 (links to maintenance order)

Damage Code & Root Cause Workflow

Damage codes (Schädigungen) → categorize what broke

• Table maintained in: SPRO → Plant Maintenance → Notification → Configure Notification Type → Damage Codes
• Example: BEARING (Lagerschaden), SEAL (Dichtungsschaden), MOTOR_COIL (Motorwicklung)

Root cause codes → categorize why it broke

• Maintained in: SPRO → Plant Maintenance → Notification → Configure Notification Type → Cause Codes
• Example: OVERLOAD (Überbelastung), POOR_MAINTENANCE (Schlechte Instandhaltung), DESIGN_DEFECT

Activity codes → actions taken

• INSPECTION, REPAIR, REPLACEMENT, ADJUSTMENT, CALIBRATION

Notification Workflow

IW21 (Create) → IW22 (Edit, assign to equipment/FL) 
→ Create Maintenance Order (IW31) or Assign Existing (IW81)
→ Complete Notification (IW21 → Status = COMPLETED)
→ Archive / History Report (IW28, IW29)

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5. Maintenance Order (IW31/IW32/IW33)

Execution unit — operationalizes a notification into scheduled work with costing

Order Types & Lifecycle

Order Type	Purpose	Settlement	Workflow
PM01	Preventive maintenance	Cost center or internal order	Recurring
PM02	Breakdown maintenance	Cost center or internal order	Ad-hoc
PM03	Corrective action / temporary fix	Internal order	One-time
PM10	Maintenance by vendor/contract	Purchase order line	Outsourced
ER01	Emergency order (fast-track)	Cost center	Expedited release

Lifecycle (Status Flow)

CRTD (Created) → PLAN (Planning) → RELD (Released) 
→ TECO (Technically Complete) → CLSD (Closed)

Key transitions:

• CRTD → RELD: IW32 (Change) → Release button (Authorization: PM.ORD.R)
• RELD → TECO: CO11N (confirmation) or manual in IW32
• TECO → CLSD: Settlement (KO88) → automatic CLSD after successful posting

Key T-codes

T-code	Description
IW31	Create maintenance order
IW32	Change maintenance order
IW33	Display maintenance order
IW38	Maintenance order list (with statuses)
IW39	Maintenance order analysis (OLAP)
COOIS	Production order info system (includes maintenance orders)

Critical Fields (AUFK + AFKO + AFIH Tables)

Field	Table	Meaning	Key Link
AUFNR	AUFK	Maintenance order number	12 digits
AUART	AUFK	Order type (PM01, PM02...)	Defines cost collection rules
EQUNR	AUFK	Equipment	Equipment master (EQUI)
TPLNR	AUFK	Functional location	FL master (IFLO)
QMNUM	AUFK	Notification reference	Notification (QMEL)
KOSTL	AUFK	Cost center (account assignment)	GL posting account
INAUFNR	AUFK	Internal order (account assignment)	Alternative to cost center
ERDAT	AUFK	Creation date	Audit trail
GSTDT	AUFK	Scheduled start date	Capacity planning
GETDT	AUFK	Scheduled end date	Capacity planning
FZDAT	AUFK	Actual start date	Filled by TECO or confirm
FZEND	AUFK	Actual end date	Filled by TECO or confirm
GGRTXT	AUFK	Order description	40 chars
MGVST	AUFK	Total planned labor hours	Sum of operations (AFIH.LAH)
STATUS	JEST	Order status (via object key AUFK + status cat P)	Links to JEST table (status management)

Operations & Component Planning

Operations (AFIH table) — individual tasks within maintenance order

Field	Meaning	Type
LTEXT	Operation description	Text, e.g., "Replace pump seal"
LAH	Standard labor hours	Decimal, e.g., 4.5
MGH	Standard machine hours	Used for resource capacity planning
ARBPL	Work center	CR01 resource (e.g., MAINT_TEAM_A)
LTXA	Operation long text	Detail work instructions

Components (BOM link) — spare parts required

• AFIH → STPO (BOM item) → material + quantity
• Component status: Available / Withdrawn / On PO / Missing (CO24)
• Backflush: if enabled, components auto-issue at confirmation (MIGO 261 automatic)

Maintenance Labor & Costs

Labor hours collection (CO11N confirmation)

• Actual labor time entered at operation level
• Overtime multipliers applied (customizable per order type)

Spare parts cost (MIGO)

• GI from warehouse → MIGO 261 → charged to maintenance order
• Vendor-supplied parts → PO line → GR → invoice → cost posting

Overhead allocation (KO88)

• Settlement rule: Actual cost + overhead (%) → Cost center or internal order
• Example: Order cost = 5,000 EUR → + 20% overhead = 6,000 EUR → posted to cost center

External Services (Subcontracting)

• Maintenance order header → Services tab → Create purchase requisition (BANF)
• Service material type: automatically creates PR → RFQ → PO → GR → IV (MIRO)
• Typical service materials: OUTSOURCE_REPAIR, INSPECTION_LABOR

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6. Preventive Maintenance (IP01/IP10/IP30)

Automated scheduling of recurring maintenance tasks

Maintenance Plans (IP01/IP02)

T-code	Description
IP01	Create maintenance plan
IP02	Change maintenance plan
IP03	Display maintenance plan
IP10	Call object scheduling (run planner)
IP30	Deadline monitoring

Plan Types

Plan Type	Trigger Condition	Interval
Time-based (Z1)	Calendar days	e.g., every 30 days, every 1 January
Counter-based (Z2)	Equipment counter (QMSREC)	e.g., every 10,000 operating hours
Multiple-counter (Z3)	Multiple counters (e.g., hours + days)	Whichever comes first
Performance-based (Z4)	Equipment performance KPI	e.g., when efficiency drops below 95%

Maintenance Strategy (IP11)

Strategy = grouping of maintenance tasks → optimize scheduling

Example: Monthly production line maintenance (STRAT_PRODLINE_M)

• Task 1: Bearing lubrication (5 hours, cost center MAINT_OIL)
• Task 2: Filter replacement (3 hours, material M-FILTER-001, cost center MAINT_PARTS)
• Task 3: Inspection (4 hours, cost center MAINT_LABOR)
• Total plan: 12 labor hours, materials + labor cost per execution

Scheduling Strategy (IP11 → PLTYP / IPRFL Table)

Field	Meaning	Example
BESCHREIBUNG	Strategy name	"MOTOR_BEARING_MAINTENANCE"
MPLNR	Maintenance plan number	"MPLAN-MOTOR-001"
IPRFL	Task list (group of tasks)	"TASKLIST-BEARING-005"
ISCHA	Scheduling parameter	e.g., "EVERY_30_DAYS"
LETWZ	Calendar rule	"MON" (Monday), "D" (daily)
MAINT_TYPE	Maintenance type	"PREVENTIVE", "PREDICTIVE"

Task Lists for Maintenance (IA01/IA05)

Reusable checklists & instructions

T-code	Description
IA01	Create task list (general)
IA05	Create task list (maintenance)
IA06	Maintain task list status

Task list structure (PLKO + PLPO)

• Header: task list ID, description, equipment/FL applicable
• Operations: step 10, 20, 30... each with work center + time + materials

Example: Pump Inspection Task List (TASKLIST-PUMP-INSPECT)

Step 10: Visual inspection (0.5 hrs, work center: MAINT_VISUAL)
Step 20: Vibration check (1.0 hr, equipment: VIBRATION_METER)
Step 30: Temperature measurement (0.5 hrs, sensor: TEMP_PROBE_001)
Step 40: Oil sampling (0.25 hrs, material: OIL_SAMPLE_BOTTLE)
Step 50: Report findings (0.5 hrs, work center: MAINT_ADMIN)
Total: 2.75 hours

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7. Maintenance Scheduling (IP10 / IP30)

IP10 — Call Object Scheduling

Generates notifications/orders based on maintenance plans

• Input: maintenance plans (IP01) + current equipment state
• Output: QMEL (notifications) or AUFK (orders) for upcoming maintenance
• Run frequency: typically nightly batch (transaction SM36)

IP30 — Deadline Monitoring

Tracks which equipment is overdue for maintenance

Status	Meaning
Green	On schedule
Yellow	Within lead time (e.g., due within 5 days)
Red	Overdue

Usage:

• Filter by: planning plant, work center, priority
• Action: create maintenance orders (IW31) for overdue items

Counter Readings (QMSREC Table)

Equipment counters — track usage-based maintenance triggers

Counter Type	Example	Unit
Operating hours	Production line hours	Hours
Cycles	Number of production runs	Cycles
Distance	Vehicle mileage (for mobile equipment)	km
Quantity	Material processed (e.g., tons in cement plant)	Units

Recording counter reads:

• QM04: Single equipment counter read
• QM05: Multiple counters (batch entry)
• Readings feed into IP10 scheduling → if counter >= threshold, create notification

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8. Breakdown Maintenance & MTBF/MTTR

Breakdown Notification Entry (IW21)

Operator or manager reports failure:

1. IW21 → Equipment/FL + Damage code + Priority
2. System creates notification (e.g., NOTIF-2024-001234)
3. Assign to maintenance team (ARBPL — work center)
4. Create order (IW31 with order type PM02)
5. Release order (RELD status) → work begins
6. Confirm completion (CO11N) → TECO
7. Settle order (KO88) → cost posted

Malfunction Start/End Time (QMEL / QMIH)

Field	Table	Meaning	Impact on KPI
MERDAT	QMEL	Time failure reported	Start of downtime clock
BEGDA	QMIH	Planned start of repair	Used in SLA tracking
FZDAT	AUFK	Actual repair start	Marks crew dispatch time
FZEND	AUFK	Actual repair end	End of downtime

Downtime calculation:

• Total Downtime = FZEND - MERDAT
• Repair Time (MTTR) = FZEND - FZDAT
• Waiting Time = FZDAT - MERDAT (can indicate logistics delay)

MTBF (Mean Time Between Failures) Calculation

Formula: Total Equipment Uptime / Number of Failures

Uptime period: INBDT (startup date) to current date or end date

Failure count: Sum of notifications with SCHAD = malfunction codes

SAP tracking:

• EQUI-INBDT: equipment startup date
• QMEL count by equipment (table function: SELECT COUNT(*) FROM QMEL WHERE EQUNR = 'PUMP-001')
• MTBF = (days_operating) / (failure_count)

Example:

• Equipment MOTOR-001 startup: 2022-01-01
• As of 2024-04-12: 861 days operating
• Malfunction notifications: 12 failures
• MTBF = 861 days / 12 = 71.75 days average between failures

MTTR (Mean Time To Repair) Calculation

Formula: Total Repair Time / Number of Repairs

Repair time sourced:

• AUFK.FZEND - AUFK.FZDAT (actual hours spent on repair)
• Includes: labor hours (CO11N) + external service time (if PO-based)

SAP tracking:

• Table AUFK: all PM02 (breakdown) orders
• Filter: EQUNR = equipment + ORDER_TYPE = PM02
• Calculate: SUM(FZEND - FZDAT) / COUNT(*) = MTTR

Example:

• Motor MOTOR-001: 8 breakdowns over 12 months
• Total actual repair hours logged: 44 hours
• MTTR = 44 / 8 = 5.5 hours per breakdown

KPI Reporting (IW28/IW29)

IW28 — Notification Listing

• Standard SAP query: All notifications with filters (date range, equipment, status)
• Output: Excel-friendly listing with damage code, priority, creation date, completion date

IW29 — Notification Analysis (OLAP)

• Multidimensional analysis: Equipment × Damage Code × Month
• Drilldown: which equipment/codes are failure-prone
• Used to drive preventive maintenance plan decisions

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9. Refurbishment & Serial Number Management

Equipment Refurbishment (Instandsetzung)

Complete overhaul of equipment — treated as major maintenance project

Order type: PM03 or special project order

Process:

1. Create maintenance order (IW31, order type PM03)
2. Assign refurbishment checklist (task list IA05)
3. GI all old/faulty parts (MIGO 261)
4. GR refurbished components (MIGO 101)
5. Update equipment master with new serial numbers if components replaced (IE02)
6. Confirmation (CO11N) → record actual hours + components replaced
7. Settlement (KO88) → post refurb cost to internal order or asset

Serial Number Management (SERGE / EQUI-SERGE)

Link between equipment and material master (MATNR)

Setup in Material Master (MM01)

• Org level: Plant
• Accounting view: Valuation class + Serial Number Profile (MMSL field)
• Serial Number Profile (MMSL):
  • Determines if serial numbers are required (batch posting) or optional (normal)
  • e.g., MMSL = "001" → Serial number required for all GR/GI of this material

Recording Serial Number in Equipment (IE01/IE02)

Field: EQUI-SERGE (equipment serial number)

• Max 30 chars
• Validated against material's serial number profile
• Used in: warranty tracking, spare parts traceability, recall management

Serial Number Change History (EQUZ)

Automatic log in EQUZ table

• Timestamp, user ID, old serial → new serial
• Useful for: component replacement audits, warranty period recalculation

Example: Motor Refurbishment Event

• Equipment MOTOR-001, Original Serial: "MOT-12345-ABC"
• Refurb replaces motor, New Serial: "MOT-67890-XYZ"
• EQUZ records: Date, User, Field=SERGE, Old=MOT-12345-ABC, New=MOT-67890-XYZ
• Warranty restart: if refurb qualifies, set INBDT to refurb completion date

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10. PM-CO Integration & Cost Collection

Settlement (KO88)

Posts maintenance costs from AUFK to receiver (cost center or internal order)

Key T-codes:

• KO88: Settle individual order
• KO8G: Settle multiple orders (batch)
• KO8K: Maintain settlement rule (assignment of order type → receiver type)

Settlement Rule Setup (SPRO → Controlling → Orders → Settled Costs)

Rule ID	From (Order Type)	To (Receiver)	Cost Element
RULE-PM01	PM01 (preventive)	Cost center + 400100 (PM labor)	400100
RULE-PM02	PM02 (breakdown)	Cost center + 400200 (Repair)	400200
RULE-PM03	PM03 (refurb)	Internal order + project code	400300

Variance Calculation (KO88 — Simulate before Actual)

Variance categories:

1. Input price variance (ABV): Material cost differences (actual price ≠ standard price)
2. Input quantity variance (AMV): More/fewer materials used
3. Overhead variance (SCRAP): Overhead surcharge % deviation
4. Remaining input (RESTINPUT): Unconfirmed costs still open

Best practice:

• Always run KO88 with "Simulate" first (F8 or simulation button)
• Review variance report → approve variances if acceptable
• Run actual settlement separately → creates FI documents (Controlling: 1200 Maintenance Costs)

Cost Planning (KALKULATIONSSCHEMA)

Annual maintenance budget planning — by equipment category, order type, cost center

Example budget structure:

• Category: Motors → Preventive (PM01) budget = 50,000 EUR
• Category: Motors → Breakdown (PM02) budget = 30,000 EUR (contingency)
• Total annual motor maintenance budget = 80,000 EUR

Tracking:

• AUFK-KOSTL → cost center commitment
• Monthly report (S_ALR_87013612 — Cost Center Actual vs. Budget) → compares maintenance spend vs. plan

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11. ECC vs S/4HANA — PM Specific Differences

Feature	ECC 6.0	S/4HANA
Notification tables	QMEL, QMIH, QMSM (separate)	Simplified data model; same QMEL but CDS views (I_MaintenanceNotification)
Equipment table	EQUI, EQUZ, EQAO (sparse)	EQUI same, but ZN prefix views for S/4 (C_EquipmentActive)
Maintenance order status	JEST (complex, multi-object)	JEST same but MBC (Maintenance Business Config) replaces IMG
Fiori apps	Limited (IW21, IW31 desktop)	My Maintenance Notifications (fiori), My Work Orders (fiori), Equipment Health Dashboard (Analytics)
Mobile maintenance	Mobile client (add-on)	SAP Asset Manager (native iOS/Android) — real-time counter reads, photo capture
Preventive maintenance	IP10 (batch scheduler)	IP10N (HANA-optimized) + Predictive Maintenance (SAP Data Intelligence, PAI) integration
Reporting	IW28, IW29 (ALV)	IW28/IW29 same, BUT Analytics Cloud (SAC) dashboards + Predictive MTBF modeling
GR/IR for spare parts	Standard MIGO 101/261	Same, but embedded eWM (optional storage location barcode scanning)
External services	PO-based services in order	Same, but integrated procurement (SAP Fieldglass if on Cloud)
Serial number	Manual IE02 or GR barcode scan	Automatic scanner integration (IoT) in Asset Manager
Integration to PM	MES external interface (IDOC, RFC)	Native REST API for counter pushes from MES / Predictive Maintenance Engine
User authorization	PFCG (single-user role)	SAP_BR_PLANT_MAINTENANCE role (Fiori-based) — simplified role model
Equipment history	EQUZ log only	Equipment history + Process intelligence (audit trail of all changes)

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12. 한국 현장 특이점 (Korean Manufacturing Context)

삼성/LG/현대 공장의 SAP PM 운영 특징

설비 가동률 (Equipment Availability) 관리

• 한국 제조 표준: 최소 95% 가용율 목표 (글로벌 85% vs)
• 목표 달성: 예방보전 비율 70%, 고장정비 비율 30% 이상
• SAP tracking: IW29 → "설비가동 중단 시간 분석" 월간 report (OEE 연계)

3교대 근무 환경에서의 설비 관리

• Maintenance team: 24시간 교대근무 (Day / Evening / Night shifts)
• Notification 입력: 실시간 (각 라인의 작업자 → QMS 담당자 → PM팀에 자동 통보)
• 야간 고장 처리: 긴급 외주(Emergency Vendor) 연동 (AUFK.AUART = ER01)
• 근무 시간 외 작업 (야간할증 30%): CO11N 확인 시 "야간작업" 활동코드로 구분

안전관리와 PM 법적 연계 (산업안전보건법 제23조)

• 설비점검 이력: 무조건 5년 보관 (SAP Archive에 IW28 스냅샷)
• 부정기 점검 기록: QMEL-AUFK 링크 완전성 검증 필수 (감시원 감사 대비)
• 위험설비 (크레인, 보일러, 압력용기): 고용노동부 특별감시 → PM과 QM 완전 통합
  • 고장코드 SCHAD = "PRESSURE_RELIEF_FAIL" 발생 시 자동으로 QM 검사 오더(QM10) 생성
  • AUFK → QAIN (inspection) → 외부검사기관 위탁 처리

MES ↔ SAP PM 실시간 연동

• MES (현대 DAPS, LG MES) → 설비 상태 센서 데이터 → 5분 간격 HTTP/SOAP 호출
• SAP BAPI: BAPI_EQUI_SET_COUNTER → Equipment counter 자동 갱신
• Trigger: Counter >= Preventive Maintenance Threshold → IP10 자동 IP30 Yellow 상태 전환
• Example: Motor operating hours 10,000 threshold → MES 전송 → SAP 자동 "점검 예정" notification

외주 보전 관리 (Contract Maintenance with Vendors)

• 전문 정비업체 위탁: AUFK.AUART = PM10 + Purchase Order (ME21N) 연동
• 위탁사 작업 추적: Vendor EQUI-MFBF (equipment responsibility matrix) → 정기 외주사별 KPI 평가
• 비용: PO line → GR (MIGO 101 services) → IV (MIRO) → Cost analysis (KO88 settle to cost center)

설비별 소비자부품 (Consumable Parts) 자동 발주

• 고빈도 부품: 오일, 필터, 그리스, 밀폐제 등
• PM 예방점검 task list → 필요 부품 자동 생성 (AUFK → PR → PO auto-release)
• Example: IP01 "Monthly bearing maintenance" → Task List에 "10kg Lubricant XYZ" 지정
• → IP10 실행 시 자동으로 PR 생성 → 구매 부서 자동 승인 (workflow) → PO release

설비 성능 성과금(Incentive) 관리

• KPI 연계: MTBF ≥ 90 days → PM팀 보너스 10%, MTTR ≤ 4 hours → +5%
• 월간: IW29 OLAP → Equipment별 MTBF/MTTR 계산 → 급여 시스템(HR) 연동 (BAPI_PAYROLL_PROCESS)

설비 감가상각과의 연계 (Asset Management Integration)

• Equipment EQUI-MATNR → Asset Master (AA) 자동 링크 (S/4: AA → FIAA table)
• Maintenance cost tracking: AUFK 누적비용 / Asset net book value > 60% → 기업회계 기준 "경영상 결정" 입력
• Example: Motor 구입가 100,000 EUR, 누적 maintenance cost 63,000 EUR → 신규 구입 검토 요청

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13. Standard Response Format

Follow sapstack Universal Rules:

Issue → Root Cause → Check (T-code + Table.Field) → Fix (Steps) → Prevention → SAP Note

Example: "Equipment shows MTBF 15 days — why so low?"

Issue: Motor MOTOR-001 has 8 failures in 4 months (MTBF = 15 days)

Root Cause Hypotheses:

1. Wrong damage/cause codes → notifications clustered by operator error
2. Operator misuse (overloading) → URSACHE = USER_ERROR
3. Design defect or component batch issue → QMSM-SERGE links to defective serial lot
4. Preventive maintenance never executed → check IP30 deadline monitoring

Check:

IE03 → MOTOR-001 → Equipment History tab (EQUZ)
IW24 → Filter EQUNR=MOTOR-001, date range 4 months
  → Count notifications (QMNUM)
  → Examine QMIH-URSACHE field (root cause codes)
IW28 → Report "Failure Frequency by Equipment & Cause"
  → Identify if URSACHE concentrated (indicates pattern)
IP30 → Search MOTOR-001
  → Check if any preventive tasks overdue (RED status)

Fix (if preventive maintenance overdue):

1. IP01 → Find assigned maintenance plan for MOTOR-001
2. IP10 → Force run "Deadline monitoring for plant ZPLANT"
3. Create overdue notifications for missed deadlines
4. Assign maintenance orders (IW31) + release (RELD)
5. Schedule work teams

Fix (if root cause = design defect):

1. Create RFC ticket with equipment vendor
2. Escalate to engineering (via AUFK internal order for redesign project)
3. Flag equipment in IE02 with equipment status "Restricted" (IFLOTA flag)
4. Increase spare parts stock (MM41) until replacement arrives

Prevention:

• Establish PM02 order type cost tracking → identify underbudgeted equipment
• Monthly review: IW29 MTBF by equipment class → correlate with age/design
• Upgrade task lists (IA05) → add inspection interval reduction for high-MTBF items
• Training: operator notification accuracy (damage codes) via HR learning module

SAP Notes (if applicable):

• Check SAP Support Portal (OSS) for "equipment MTBF analysis" + equipment model

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14. References

• references/ko/quick-guide.md — Maintenance order creation workflow (fast path)
• references/ko/SKILL-ko.md — Korean field language guide for PM terms
• SAP Help: SAP PM module documentation (https://help.sap.com/docs/SAP_S4HANA_CLOUD/plant_maintenance)
• Configuration: SPRO → Plant Maintenance (all customization)
• Table documentation: EQUI, IFLO, QMEL, AUFK, IP01 (F1 in SAP GUI)