SAP Plant Maintenance implementations fail most often not because of poor configuration, but because the underlying maintenance logic was never validated against how the facility actually operates. Asset hierarchies are copied from templates. Task lists reflect vendor recommendations rather than observed failure patterns. Preventive maintenance intervals are set without reference to condition data.

This engagement covers the full spectrum: greenfield implementation structuring, optimization of existing live systems, and remediation of inherited configurations that no longer reflect operational reality. Work includes functional module configuration, asset master data strategy, task list design aligned with technician workflow, and documentation suitable for regulated environments.

Proven in pharmaceutical, automotive, and industrial facilities. Delivered within ABB/SEAM Group frameworks and independently through Optago Systems.

Field-level predictive diagnostics using infrared thermography, airborne ultrasound, and vibration analysis. All three disciplines are performed directly — not subcontracted — which means the engineer reading the data is the same engineer who collected it.

Thermographic surveys identify electrical hotspots, insulation degradation, overloaded circuits, and mechanical friction points before they become failures. Airborne ultrasound detects compressed air leaks, steam trap failures, and early-stage bearing defects. Vibration analysis identifies imbalance, misalignment, resonance, and bearing wear in rotating equipment.

Engineering reports from each survey are structured to support maintenance planning decisions directly — not to fill a compliance archive.

Reliability-Centered Maintenance methodology and Failure Mode & Effects Analysis are tools for making defensible decisions about what maintenance to do, how often, and what to do when a failure occurs. Applied correctly, they reduce unnecessary maintenance, identify the tasks that actually matter, and build a maintenance program that can be justified and audited.

This engagement covers facilitation of RCM and FMEA workshops with engineering and operations teams, translation of outputs into SAP PM task structures, and documentation that supports both internal maintenance planning and external audit requirements.

An independent review of an existing maintenance program — SAP PM structure, data quality, task logic, execution compliance, and reliability performance indicators. The output identifies the gap between what the system says is happening and what is actually happening on the floor.

Audit findings are structured to support a business case for targeted improvement, not to produce a report that sits on a shelf. Recommended actions are prioritized by operational risk and implementation effort.

Maintenance compliance frameworks for regulated environments — pharmaceutical, food-grade, and other facilities operating under GMP or equivalent standards. Work covers LOTO/LOTO procedure development, maintenance documentation structure, and the alignment of SAP PM records with audit requirements.

Standards applied include ISO 55000, ISO 14224, NFPA 70E, and GMP guidelines. Documentation is written at the level that survives an external audit — clear, traceable, and matched to actual operational practice.

Practical training for maintenance teams, reliability engineers, and SAP PM users. Not generic classroom content — sessions are built around the participant's own systems, their actual asset failures, and the decisions they need to make on a daily basis.

Formats include on-site workshops, remote sessions, and coaching programs for individual engineers. Topics covered: SAP PM functional use, predictive maintenance interpretation, RCM facilitation, FMEA workshops, and maintenance strategy development.

A migration moves what exists in the source system into the new one — including every structural problem, every inconsistency, and every piece of maintenance logic that was never validated. The quality of EAM data post-migration is determined almost entirely by what was done to the data before the migration ran.

This engagement covers asset master data validation and cleansing, functional location hierarchy review, preventive maintenance task list assessment, maintenance history evaluation, and measurement point and BoM / spare parts data integrity — across the full range of migration scenarios: SAP ECC to S/4HANA, CMMS-to-SAP (Maximo, Infor, and others), legacy spreadsheet or paper-based systems entering SAP PM for the first time, and post-migration remediation where data quality issues became visible only after go-live.

The distinguishing factor in this work is operational context. Data fields can be checked by a data analyst. Whether the asset hierarchy reflects the physical plant, whether the PM intervals are defensible, whether the task lists describe work that technicians can actually execute — those questions require someone who understands what the data is supposed to represent. That is the specific competency Optago Systems brings to migration projects.