The flowchart illustrates the Shutdown Maintenance process in SAP, integrating modules such as Plant Maintenance (PM), Materials Management (MM), and Financial Accounting & Controlling (FICO). The shutdown maintenance process in SAP Plant Maintenance (PM) is a structured approach to managing maintenance activities during a planned shutdown of equipment or facilities.

Following is the break down of process shown in flowchart image:

🛠️ Plant Maintenance (PM) Activities

• Create Shutdown Maintenance Order (Transaction: IW31 or IW32): The process begins with creating a specific maintenance order for the shutdown. This order serves as the central point for planning, executing, and tracking all activities related to the shutdown maintenance. It’s crucial to use a specific order type that’s configured for shutdown maintenance to ensure proper cost allocation and reporting.
• Assign Functional Location/Equipment for Shutdown Maintenance Order: In this step, the specific functional location or equipment that will undergo shutdown maintenance is assigned to the order. This assignment is critical for accurate tracking of maintenance history and costs associated with the particular asset or area of the plant.
• If Required Get Approvals from Management: Depending on the scope and impact of the shutdown, approvals may be required from various levels of management. This step ensures that all stakeholders are aware of the planned shutdown and its potential impact on operations and finances.
• Once Approved Cross Verify Plant Machinery for Shutdown Activities: After receiving approvals, a thorough verification of the plant machinery involved in the shutdown is conducted. This step helps in finalizing the scope of work and identifying any additional equipment that might be affected by the shutdown.
• Maintenance Order Planning: This is a crucial step where all the activities, resources, and materials required for the shutdown are planned in detail. It involves:
  1. Defining work packages
  2. Scheduling activities
  3. Allocating resources (both internal and external)
  4. Identifying required materials and services
• If Spares Required from Store (Yes/No): This decision point determines whether spare parts are needed from the store for the maintenance activities.
  1. If Yes: A reservation for stock material is created (Transaction: MB21)
  2. If No: The process moves to check if non-stock materials are required
• PR for Non-Stock Material: If materials not available in stock are required, a purchase requisition (PR) is created for these items.
• Services Internal/External Service (Yes/No): This decision point determines whether internal resources are sufficient or if external services are needed.
  1. If Yes (Internal): The process moves directly to performing maintenance
  2. If No (External): A PR for external service is created
• Perform Maintenance/Confirmation: The actual maintenance work is carried out during the shutdown period. As work progresses, confirmations are made in the system to track completion of activities.
• Time Confirmation & Complete Confirmation (Transaction: IW41): Time spent on various activities is recorded, and completions are confirmed in the system. This step is crucial for accurate cost allocation and progress tracking.
• Technical Completion for Order (Transaction: IW32): Once all maintenance activities are completed, the order is marked as technically complete in the system.

📦 Materials Management (MM) Actions

• Goods Issue Process (Transaction: MB1A): Reserved materials are issued from the store for the shutdown maintenance activities.
• Create PO for Non-stock/External Service (Transaction: ME21N): Purchase orders are created based on the PRs for non-stock materials and external services.
• Is it Service PO? (Yes/No):
  1. If Yes: A service entry sheet is created (Transaction: ML81N)
  2. If No: The goods receipt process is initiated
• Goods Receipt Process (Transaction: MIGO): For material POs, goods receipts are processed when items are received.
• Service Entry Sheet: For service POs, service entry sheets are created to record the services provided during the shutdown.

💰 Finance/Controlling (FICO) Steps

• Invoice Verification Vendor Payment (Transaction: MIRO): Invoices for materials and external services used during the shutdown are verified and processed for payment.
• Business Completion for Order: The shutdown maintenance order is marked as complete from a business perspective, indicating that all activities and financial transactions related to the shutdown are finalized.
• Settlement for Order (Transaction: KO88): All costs associated with the shutdown maintenance are settled to the appropriate cost centers or projects.

This Shutdown Maintenance process demonstrates the complex coordination required between different SAP modules to manage large-scale maintenance activities efficiently. It ensures proper planning, execution, and financial control of shutdown maintenance, minimizing downtime while maximizing the effectiveness of maintenance work.

📚Useful resources for Shutdown Maintenance Process in SAP PM:

• Shutdown Maintenance Process Guide in SAP PM (PDF)