Plant Maintenance
Equipment that costs more to keep than to replace
Equipment, work orders and downtime: the cost of keeping a machine set against what it would cost to stop.
See it answer one of theseAsk it
Questions you can ask on day one
Asked in plain language. Each answer prints the SAP entity, field and period it was computed from, underneath the figure.
- “Which equipment costs more in downtime than it would to replace?”
- “What is failing most often, and where?”
- “Which maintenance orders are overdue?”
- “How much have we spent on unplanned work this year against planned?”
- “Which functional locations generate the most notifications?”
- “How long are breakdowns staying open, by equipment type?”
What it reads
The maintenance objects behind an answer
Equipment and functional locations
The asset hierarchy: what exists, where it sits, and what it belongs to.
Maintenance orders
Planned and unplanned work, with costs, dates and the order types that separate one from the other.
Notifications
Breakdowns and requests as they were reported, with how long each stayed open.
Operations and confirmations
The labour and time actually booked against an order, which is where maintenance cost becomes real.
Measurement documents
Readings taken against a piece of equipment over time, where your system records them.
Why it is hard
What no standard report does for you
Cost of downtime is not a field anywhere
It is assembled: the labour booked against orders, the frequency of failure, and the time the asset was unavailable. Each piece lives somewhere different, and the figure nobody has is the one that would actually decide a replacement.
Planned and unplanned only separate by convention
The distinction lives in order types your business configured. A question about unplanned spend has to know which types mean what, which is exactly the local knowledge that leaves when somebody changes role.
Failure frequency is an aggregate nothing stores
Each notification is a document. That a particular pump has generated nine of them this year is a count across a window, visible only when somebody groups by equipment and looks.
The figure that would decide it
Every maintenance organisation has a handful of assets everybody suspects are not worth keeping. The evidence is scattered: labour booked over years, a notification history nobody has counted, downtime that was felt rather than recorded in one place.
Assembling it takes a person a week, which means it is assembled when somebody is already arguing about a capital request rather than before.
Assembled, not stored
What AnrilX can do is put the pieces together on demand: cost booked against a piece of equipment over a window, how often it has failed, how long it stayed down where your system records that. Each with the entity it came from printed underneath, so the numbers survive being questioned in a meeting.
What it will not do is invent the half that is not in the data. Replacement cost is not in your maintenance module, so the comparison stays yours to make; the platform’s job is to make one side of it take seconds rather than a week.
Conventions travel with the answer
Planned against unplanned is a distinction your business encoded in order types. A figure that depends on that convention names the types it counted, which is what lets somebody who knows the configuration confirm it, or notice immediately that a type has been miscategorised.
One of these questions, answered
Which equipment costs more in downtime than it would to replace?
Four assets. Press 1140-A is the clearest case: 31 unplanned hours this year against a line rate that puts the lost output at 1.44m SAR, on an asset whose replacement is quoted at 900k. The comparison is rarely made because the downtime sits in maintenance and the value of the output does not.
Source: A_MaintenanceOrder and I_EquipmentDowntime · unplanned downtime hours by Equipment · valued at the work centre line rate · replacement value from the asset master
Assumed: downtime cost is lost output at the line rate, not maintenance labour and parts. Those are also real and are a much smaller number, which is why a maintenance cost report does not surface any of these.
Where it stops
What it will not answer here
The limits particular to this module. Worth knowing before a pilot rather than during one.
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Replacement cost is not in the maintenance data. The platform reports what upkeep has cost; comparing that against a replacement price is a decision it supports rather than makes.
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Planned versus unplanned reflects the order types configured in your system. Where that convention is inconsistent, the figures inherit the inconsistency and the answer names the types it counted.
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Downtime is derived from what your system records. Where availability is not tracked, the platform says so instead of estimating it.
Questions people ask us
Can it tell us what a machine has cost us?
It reads what has been booked against that equipment (orders, operations, confirmations) and totals it over the window you name, naming the entities it read. Whether that justifies replacement is your call; the figure is the input to it.
Can it separate planned from unplanned work?
Yes, by the order types your system uses, and it names the types it counted so you can confirm they mean what you expect.
Does it predict failures?
Forecasting works from history in your own system and reports its error rate alongside any figure. Where the history is too sparse to support a forecast, it says so rather than producing a number.
Questions often cross into
Which orders are exposed to something that has not arrived
Production orders, operations and component demand: where a schedule is exposed to something that has not arrived yet.
Which defects keep coming back from the same supplier
Inspection lots, defects and notifications, traced back to the supplier, the batch and the process step that produced them.
Purchasing, read at the grain the money sits on
Purchase orders and their items, goods movements, supplier invoices and info records, with spend sitting on the item, where it actually lives.
Bring the question your reports cannot answer
Thirty minutes against a live SAP system we provide: no access to yours, nothing to set up. If it cannot answer, you find that out in half an hour rather than three months into a pilot.