pm-006維修求和更正性訂單的創(chuàng)建流程maintenance request and corrective order process

協(xié)同商務(wù)體驗CollaborativeBusinessExperience?藍(lán)圖設(shè)計文檔—維修請求和更正性維修訂單的創(chuàng)建流程BlueprintDocument—MaintenanceRequestandCorrectiveMaintenanceOrderProcess慧眼項目ProjectInsight華新水泥HuaxinCement版本Version1.12007/09/19InsightSAPPilotBlueprintDocumentVersionx.0 -PAGE2-InsightSAPPilot作者AUTHOR作者Author聯(lián)系方式ContactInfo李玨林LiJuelin電子郵件Email:lijuelin@電話Phone訂REVISION日期Date文檔版本Version修訂描述Description文檔作者Author2007/09/191.0初始版本First李玨林LiJuelin2007/09/291.1第二版本Second李玨林LiJuelin審批APPROVAL審批日期Date審批版本Version審批人角色ApproverRole審批人ApproverYYYY/MM/DD1.0姓名Name: -PAGE21-InsightSAPPilotFILENAMEPM-006-維修請求和更正性維修訂單的創(chuàng)建流程_20070929B.docLastsavedbyLASTSAVEDBYFrankBingJinYouLASTSAVEDBY目錄TOC\o"1-3"\h\z1. 流程說明ProcessDescription 11.1. 在流程層次結(jié)構(gòu)中的位置PositiononProcessHierarchy 11.2. 適用范圍Areaofapplication 11.3. 聯(lián)系人（關(guān)鍵用戶）Contactperson(Key-User) 11.4. 術(shù)語Terms 11.5. 流程目的和范圍Processgoalsandscope 31.6. 差異分析GapAnalysis 31.7. 維修請求和更正性維修工單的創(chuàng)建流程圖MaintenanceRequestandCorrectiveMaintenanceOrderprocess 41.7.1. 保險處理和資本性支出的判斷子流程流程圖InsuranceHandlingandCAPEXIdentificationSub-process 61.8. 業(yè)務(wù)步驟說明Descriptionofprocesssteps 81.8.1. 保險處理和資本性支出的判斷（子流程）流程說明InsuranceHandlingandCAPEXIdentificationSub-processdescription 91.9. 其他說明OtherInformation 91.10. 改進(jìn)分析ImprovementAnalysis 111.11業(yè)務(wù)原則Businessrules 111.12其他相關(guān)文檔Crossreferencetootherdocuments 122. 技術(shù)相關(guān)信息TechnicalInformation 132.1. 接口程序Interfaces 132.2. 打印格式程序和報表Forms,Reports 132.2.1. 打印程序列表Forms 132.2.2. 報表程序列表Reports 132.3. SAP系統(tǒng)修改和用戶出口程序SAPmodification,enhancements 132.4. 使用技巧和竅門Hintsandtricks 13流程說明ProcessDescription在流程層次結(jié)構(gòu)中的位置PositiononProcessHierarchy工廠維護(hù)工廠維護(hù)PLMPlantMaintenance維護(hù)通知書維護(hù)通知書MaintenanceNotification維修請求和更正性維修工單的創(chuàng)建維修請求和更正性維修工單的創(chuàng)建PLM.NOCMMaintenanceRequestandCorrectiveMaintenanceOrder適用范圍Areaofapplication本流程適用于華新水泥股份有限公司所有生產(chǎn)型分子公司維修單位的一般可計劃的更正性維修方面的工作ThisprocessisusedformaintenancerequestandcorrectivemaintenanceworkinallproductionbranchplantofHuaxincementCO.,LTD.聯(lián)系人（關(guān)鍵用戶）Contactperson(Key-User)名字Name部門Department角色Role電話Phone郵件Email備注Remarks朱亞平Zhuyaping慧眼工程部ProjectInsight模塊經(jīng)理Modulemanagerzhuyaping@李春風(fēng)Lichunfeng慧眼工程部ProjectInsight關(guān)鍵用戶Keyuserlichunfeng@劉晅Liuxuan慧眼工程部ProjectInsight關(guān)鍵用戶Keyuserliuxuan@李玨林Lijuelin慧眼工程部ProjectInsight關(guān)鍵用戶Keyuserlijuelin@王磊Wanglei慧眼工程部ProjectInsight關(guān)鍵用戶Keyuserwanglei@周國華Zhouguohua武穴公司維修部maintenancedepartmentofWuXueplant業(yè)務(wù)專家BusinessexpertZhouguohua@術(shù)語Terms維修通知單：記錄需要維修設(shè)備的運行或故障信息，并傳達(dá)維修請求和技術(shù)信息。某些時候通知單可以在維修后補齊（如緊急維修）。它按照設(shè)備的重要性與故障對設(shè)備的影響程度分為M1、M2、M3和Z1共四種單據(jù)。Notifications:Notificationskeepoperationormalfunctioninformationofthemaintenanceobject,conveymaintenanceinformationandrequirements.Sometimesthenotificationcanbesupplementedandcompletedlater.Notificationsinclude4typesforimportantanddamageofthetechnicalobject:M1,M2,M3andZ1.維修工單：維修工單是維修的過程管理和監(jiān)控手段，指導(dǎo)維修工作以及維修計劃和維修策略的制定。維修工單通常用作計劃維修任務(wù)和記錄統(tǒng)計真實的維修活動費用，它會涉及到一個技術(shù)對象（功能位置或設(shè)備）和維修工作中心，但是某些維修工單并不具備計劃的功能（如緊急維修工單）。維修工單和通知單互相間可以獨立創(chuàng)建而沒有依賴關(guān)系，但是它們一起使用將對維修工作更加有利，維修工單包括以下四種類型：PM01更正維修工單：用來執(zhí)行修理在線設(shè)備主要或次要功能故障的活動，以及修正在線設(shè)備在安裝與設(shè)計方面有缺陷的活動而產(chǎn)生的工單，但符合公司資本性支出規(guī)定的維修則應(yīng)使用投資性工單；PM02預(yù)防性維修工單：對在線設(shè)備進(jìn)行周期性維護(hù)工作而使用此工單；PM04翻修工單：將儲存在倉庫的設(shè)備維修到象新的一樣狀態(tài)，為未來的使用做準(zhǔn)備，則使用此工單；PM06投資性工單：投資性工單的使用要求符合公司資本支出管理辦法的規(guī)定。Orders:Maintenanceordersareinstrumentsformaintenanceprocesscontrolandmanagement,guidemaintenancework,maintenanceplanandstrategy.Ordersareusedtoplanmaintenancetasksandplanortrackthecostsincurred.Theorderusuallyreferstoatechnicalobject(functionallocationorequipment)andisconfiguredataworkcenter,buttheplanningfunctionsdonotnecessarily.Ordersandnotificationscanbeusedindependentlyofoneanother.However,theyareusuallycombinedtoutilizetheadvantagesofbothinstruments.MaintenanceorderswillbedefinedinSAP-PMwiththefollowingtypesanddescriptions.PM01

Corrective:Itiscreatedforanymaintenanceworkperformedonapieceofequipmenttorepairapartialorcompletefailureofanequipment'sprimaryorsecondaryfunctions,itisalsocreatedforanymaintenanceworkperformedonapieceofequipmentthatisamodificationoftheoriginaldesign,butthemaintenanceworkdoesnotmeettheguidelinesasdefinedincapitalexpendituresmaintenancerule.PM02

Preventive:Itiscreatedforanymaintenanceworkperformedonapieceofequipmentthatisperiodicorcyclicalinnature.PM04

RefurbishmentOrder:Itiscreatedforanymaintenanceworkperformedonapieceofequipmentormaterialthatwillcompletelyrestoretheequipment'soperationalcapabilityto'like-new'conditionandthisequipmentormaterialisthenstoredinthewarehouse/storeroomforfutureuse.PM06

InvestmentOrder:ItiscreatedforanymaintenanceworkperformedthatmeetstheguidelinesasdefinedinHuaxincapitalexpendituresmanagementrule.流程目的和范圍Processgoalsandscope流程目的：本流程將使故障信息的記錄和上報工作更加準(zhǔn)確與迅速，為維修工作爭取更多的時間Processgoals:Thisprocesswillrecordandconveymalfunctioninformationfasterandmoreaccurate,savemoretimetoperformthemaintenancework.流程范圍：本流程應(yīng)用于華新各生產(chǎn)基地的所有生產(chǎn)設(shè)備被發(fā)現(xiàn)發(fā)生了需要更正性維修的故障后，到更正性維修工單的創(chuàng)建或投資性工單流程啟動前的維修活動。Processscope:ThisprocessisusedformaintenanceactivityfrommalfunctionfoundtocorrectivemaintenanceordercreatedorinvestmentorderprocessstartedinHuaxincementCO.,LTD.productionbranchplant.差異分析GapAnalysis無None維修請求和更正性維修工單的創(chuàng)建流程圖MaintenanceRequestandCorrectiveMaintenanceOrderprocess保險處理和資本性支出的判斷子流程流程圖InsuranceHandlingandCAPEXIdentificationSub-process業(yè)務(wù)步驟說明DescriptionofprocessstepsNo.步驟描述StepDescription何時執(zhí)行Whenisthestepexecuted?備注Remarks1巡檢人員包括生產(chǎn)巡檢、保全、鉗工、電工和儀表工等，巡檢人員在各自相應(yīng)的巡檢表上填寫發(fā)現(xiàn)的情況與執(zhí)行的操作Walk-byInspectors(containproduct,mechanical,electricityandinstrument)fillintheirinspectingchecksheetrecordaccordingabnormalconditionfoundandworkstepfinished.當(dāng)巡檢人員發(fā)現(xiàn)設(shè)備有異?，F(xiàn)象后Afterwalk-byinspectorsfindabnormalconditionofthemaintenanceobject.填寫巡檢記錄FillininspectingChecksheetrecord2生產(chǎn)值班長、維修值班長、計劃員、工程師均有責(zé)任創(chuàng)建通知單Productionshiftsuperintendent,maintenanceshiftsuperintendent,plannerandengineerallcancreatemaintenancenotification創(chuàng)建通知單的人員收到巡檢人員的通知后，或者有設(shè)備的周期性更換及小型技術(shù)改造項目的產(chǎn)生NotificationCreatorreceivemaintenancerequirements,periodicallychangeplanforequipment,ortechnicalimprovementinminiature創(chuàng)建維修維護(hù)通知單，并通知維修計劃員Createmaintenancenotification,andinformmaintenanceplanner3進(jìn)入保險處理和資本性支出的子流程StartinsurancehandlingandCAPEXidentificationsub-process通知單創(chuàng)建完畢后Notificationshavebeencreated判斷是否需要維修和資本性支出WhethermaintenanceneededanditisCapex4相關(guān)維修計劃員根據(jù)維修方案創(chuàng)建維修工單，提出備件預(yù)留與采購申請，并啟動維修計劃與排程的流程Maintenanceplannercreatesorderaccordingtomaintenancesolution,generatereservationsandpurchaserequisitions,andstartsthenextprocess子流程里得出需要維修但不是資本性支出的結(jié)論后Sub-processresultisthatmaintainingneededanditisn’tCapex創(chuàng)建維修工單向MM提出備件預(yù)留與采購申請CreateorderwillgeneratereservationandpurchaserequisitioninMMmodule5維修計劃員及時將情況反饋給相關(guān)的巡檢人員，如果通知不到，則通知其輪班負(fù)責(zé)人Maintenanceplannerinformstheinspectorintime,andinformsshiftmonitorifneeded子流程里得出不需要維修后Sub-processresultisn’tthatmaintenanceneeded通知巡檢人員和班長Informinspectorandmonitor6維修計劃員在sap系統(tǒng)里結(jié)束通知單Maintenanceplannerclosenotification維修計劃員通知到巡檢人員后Afterplannerhasinformedtheinspector結(jié)束通知單Closenotification注：如果在維修過程中發(fā)現(xiàn)故障點和故障原因與解決方案有出入，則在維修結(jié)束后再更改相關(guān)維修工單Note:Duringthemaintenancework,ifmalfunctionpointorcausefoundisdifferentfrommaintenancesolution.Youcanchangethemaintenanceorderlater.保險處理和資本性支出的判斷（子流程）流程說明InsuranceHandlingandCAPEXIdentificationSub-processdescriptionNo.步驟描述StepDescription何時執(zhí)行Whenisthestepexecuted?備注Remarks1維修計劃員對設(shè)備按照保險范圍判斷Maintenanceplannercheckifequipmenthasbeinsuredalreadyaccordingthescopeofinsurance.通知單已創(chuàng)建，子流程已啟動Notificationhasbeencreated判斷是否投保設(shè)備Checkifequipmenthasbeeninsuredalready2維修計劃員及時通知公司保險聯(lián)系人MaintenanceplannerinformsInsuranceatonce計劃員發(fā)現(xiàn)設(shè)備已投保后，在并準(zhǔn)備維修前Beforemaintenancework,maintenanceplannerknowtheequipmenthasbeeninsuredalready通知保險聯(lián)系人聯(lián)系保險公司現(xiàn)場勘查，損壞認(rèn)證InformInsurancecontacttoaskforInsuranceCompanydoDamageVerification3維修計劃員與公司保險聯(lián)系人一道填寫索賠申請MaintenanceplannerandInsurancecontactFillInInsuranceClaimForm保險公司勘查完現(xiàn)場后Insurancecompanyhasfinisheddamageverification填寫保險索賠申請F(tuán)illInInsuranceClaimForm4維修計劃員將索賠申請交給公司財務(wù)人員，由財務(wù)人員進(jìn)行索賠操作MaintenanceplannersendsInsuranceClaimtofinanceaccountant,financeaccountantwillhandinsuranceclaim保險索賠申請產(chǎn)生InsuranceClaimFormiscreated向保險公司申報ClaimtheDamagetoInsuranceCompany5相關(guān)維修計劃員單獨或召集技術(shù)人員根據(jù)資本性支出的業(yè)務(wù)規(guī)則判斷設(shè)備的維修是否為資本性支出。如果判斷是資本性支出，則啟動投資性工單創(chuàng)建流程MaintenanceplannercanjudgeifmaintainingneededanditisCAPEXbyhimselforwithhelpofothertechniciansaccordingtheruleofCAPEX.IfCAPEX,gototheinvestmentorderprocess.本步驟可以在子流程啟動時便開始執(zhí)行，但如果發(fā)現(xiàn)是需要保險公司賠付的故障則需要等保險公司現(xiàn)場勘查結(jié)束后才能開始或并行進(jìn)行Thisstepcanbeperformedatthefirststep.ButifinsurancecompanyneedstodoDamageVerification,itcanbeperformedlaterorinparallel.決定是否需要維修以及是否資本性支出計劃員應(yīng)能根據(jù)巡檢報告和通知單研究維修方案，如有必要，可以進(jìn)現(xiàn)場考察，考察期間可以開始檢測故障點工作WhethermaintainingneededanditisCAPEX.Plannercanandshoulddothemaintenancesolutionaccordingthechecksheetandnotification.Ifnecessary,hecandothefieldworkandcheckthemalfunctionpoint.其他說明OtherInformation1．Z1通知單上的停工期將指生產(chǎn)線的停工期。Z1通知單和里面的數(shù)據(jù)將會被用于KPI方面的計算。ThedowntimeinZ1notificationswillbethedurationofthedowntimeoftheproductionline.TheZ1notificationanddataincludedwillbeusedfortheKPIcalculations.2．工廠的任何員工都可以通過任何交流方式向部門領(lǐng)導(dǎo)或高層提出維修請求，萬一出現(xiàn)緊急情況，生產(chǎn)部部長、維修部部長、維修計劃員可以直接創(chuàng)建維修工單M2，而且維修請求可以先使用電話通知，當(dāng)維修工作開始后，再將所有數(shù)據(jù)記錄在系統(tǒng)里。一般設(shè)備檢修中要基于已有的通知單生成維修工單PM01類型。Anystaffintheplantthroughanymeansofcommunicationcanraiseamaintenancerequesttoteamleaderorhigherlevel.Incaseofemergency,Productionsuperintendent,maintenancesuperintendent,andMaintenanceplannercancreatemaintenanceordertypePM01withnotificationtypeM2.therequestcanbemadebycall,afterwhichalldatawillberecordedtosystemafteramaintenancejobstart.MaintenanceordertypePM01canbecreatedforexistingnotificationinnormalcorrectivemaintenance.3．不管是計劃的還是非計劃的維修工作，為了記錄下維修的對象、癥狀、及損壞的原因，都需要有維修通知單。多個維修通知單可以生成一個維修工單，可以根據(jù)狀態(tài)從多個維修通知單選出未結(jié)的（通知單），在進(jìn)行中的、延期的及完成的。用戶能夠基于其選擇的標(biāo)準(zhǔn)列出通知單。Regardlessofplannedorunplannedmaintenancejobs,amaintenancenotificationisrequiredinordertokeeptheinformationregardingthemaintenanceobjectandtodescribetheconditionofthemaintenanceobjectsuchasobjectpart,symptom,andcauseofdamage.Multiplenotificationsareabletorefertoonemaintenanceorder.Listofmaintenancenotificationswillbeselectedbystatusasoutstanding,inprocess,postponedandcompleted.Userscanlistthenotificationsbasedontheirselectionscriteria.4．當(dāng)維修通知單被核實后，它將會轉(zhuǎn)化成維修工單，維修工作結(jié)束后，維修計劃者必須在通知單關(guān)閉之前更新技術(shù)信息，如：零部件、癥狀、損壞原因，及執(zhí)行的維修活動(包括停機(jī)故障)。并不是所有的維修請求（通知單）都將轉(zhuǎn)化為維修工單。主要取決于維修計劃者是否對維修通知單下達(dá)維修工單。沒有轉(zhuǎn)化成維修工單的維修通知單仍然可以記錄技術(shù)信息或者被刪除（設(shè)置刪除標(biāo)志）。MaintenancenotificationtypeM1-MaintenancerequestwillbeconvertedtomaintenanceordersoftypePM01afteritisjustifiedthatmaintenanceworkisrequired.Aftermaintenanceworkhasbeenfinished,maintenanceplannerhastoenter/updatethetechnicalfindinginformationsuchasobjectpart,symptom,causeofdamage,andactivitiesperformedinthenotificationbeforeclosing(includingmalfunctiondowntime).Notallmaintenancerequests(notification)willbeconvertedtomaintenanceorders.Itisuptothemaintenanceplannertoissueornottoissuemaintenanceordersfortherequests.Notificationsthatarenotconvertedintomaintenanceordercanstillberecordedtechnicalinformationorcanbedeleted(setdeletionflag).5．按MAC-SAP的標(biāo)準(zhǔn)，零部件列表、癥狀列表及原因列表將被應(yīng)用。對所有的4種維修通知單來說，癥狀編碼都是相同的。癥狀表將被用于所有的設(shè)備類型。癥狀的描述只包含癥狀的信息，在這些描述中，不包含備件及原因。癥狀的代碼從HOLCIM集團(tuán)公司中編輯的代碼，他們在SAP－PM中完善了這些代碼。通知單M1，M2，M3和Z1將使用相同的原因代碼，這些代碼是從幾家先進(jìn)的Holcim公司總結(jié)出來的。這些代碼希望找到（設(shè)備）失效的根本原因，然而技術(shù)人員仍然有可能找到更深層次的故障原因。這些原因不包含部件對象或現(xiàn)象信息。使用MAC－SAP標(biāo)準(zhǔn)表和代碼能夠幫助維修計劃員很容易的進(jìn)行故障和影響的分析。ThemandatorycatalogsthatrequiredbyMAC-SAPstandardsuchasObjectpartcatalogs,Symptomcatalogs,andCausecatalogswillbeapplied.TheSymptomcatalogsandcodeswillbethesameforallfourtypesofmaintenancenotifications.ThesameSymptomCatalogwillbeusedforallEquipmentTypes.TheSymptomdescriptionsincludeonlysymptominformation.TherearenoObjectPartsorCausesincludedinthesedescriptions.TheSymptomcodesareacompilationofcodesfrommanyoftheHolcimgroupcompaniesthatareusingtheSAPPMmoduleandwhohavedevelopedthesecodes.ThenotificationtypesM1,M2,M3andZ1willusethesameCausecatalogs.ThesecodesarebasedonacompilationofCausecatalogcodesfromseveralgroupcompaniesthathavedefinedthesecodes.Thesecodesareanattempttofindtherootcauseofafailure.

However,pleasenotethatitcansometimesbepossibletofindalowerlevelcause.TheseCausesarestrictlyCausesanddonotincludeObjectPartorSymptominformation.UsingtheMAC-SAPstandardcatalogsandcodeshelpmaintenancepersonalstoeasilyperformFMEA(FailureModeandEffectAnalysis).改進(jìn)分析ImprovementAnalysis本流程能更快速的傳遞維修請求與故障信息，便于查找設(shè)備故障和維修的歷史信息，容易組織、分類及分析該信息Thisprocesswillrecordandconveymalfunctioninformationfasterandexacter,Easytosearchforthehistoricalinformationofequipment,Easytogroup,categorizeandanalyzeinformation.1.11業(yè)務(wù)原則Businessrules1．通知單類型選擇的業(yè)務(wù)規(guī)則：維修通知單按照設(shè)備的重要性與故障對設(shè)備的影響程度分為M1、M2、M3和Z1共四種單據(jù)，其使用原則如下所示：當(dāng)任何需要維修部門執(zhí)行一個維修任務(wù)的時候，而且這個維修任務(wù)并不是因為設(shè)備主要的或次要的功能失效而引起（即設(shè)備無故障），可能只是要改善其運行環(huán)境和性能，創(chuàng)建維修請求通知單M1；當(dāng)任何需要維修部門執(zhí)行一個維修任務(wù)的時候，而且這個維修任務(wù)因為設(shè)備主要的或次要的功能的完全或部分失效造成的（即設(shè)備產(chǎn)生了故障），創(chuàng)建維修請求通知單M2；M3用于設(shè)備未發(fā)生故障，檢查人員完成了維修活動，該維修活動僅使用檢查人員隨身攜帶的工具，并且沒有發(fā)生領(lǐng)料，而需要對維修活動進(jìn)行記錄；Z1僅用于記錄大型重要設(shè)備的停機(jī)，無論停機(jī)是其自身原因造成還是其他設(shè)備影響，Z1均要使用。BusinessRuleforselectingnotificationtype:Notificationsinclude4typesforimportantanddamageofthetechnicalobject:M1,M2,M3andZ1M1-MaintenanceRequest:TheM1MaintenanceRequestnotificationiscreatedwheneverthereisanactivityneededtobeperformedbythemaintenancedepartmentandthisactivityisnottheresultofapartialorcompletefailureofanequipment'sprimaryorsecondaryfunctions.M2-MalfunctionReport:TheM2MalfunctionReportnotificationiscreatedwheneverthe