Employee safety in maintenance is a top priority, and most companies take their responsibility seriously. This commitment is reflected in the steady decline in workplace accidents over recent decades. According to the German Federal Institute for Occupational Safety and Health (BAuA), there were about 950,000 reportable workplace accidents in Germany in 2018 – around 24 accidents per 100,000 full-time employees. In comparison, the figure in 1960 was about 2.7 million accidents, or roughly 110 per 100,000 full-time employees. This encouraging trend is expected to continue in the coming years.
Important safety measures in maintenance
Maintenance plays a crucial role in employee safety, as the nature of the work involves an above-average level of risk. Data from the German Federal Institute for Occupational Safety and Health ( percent of all fatal workplace accidents are linked to maintenance activities. Given this heightened risk, it is no surprise that specific strategies have been developed to mitigate hazards and enhance safety. One key approach is the 4-level method.
The 4-level method
The 4-level method outlines four successive prerequisites for carrying out maintenance activities safely:
- Lockout‑Tagout (LOTO)
- Use-of existing machine safeguards
- Additional engineering controls
- Administrative & personal measures
Work clearance management eliminates risk
The goal is to work at the first level of the 4-level method whenever possible. In practical terms, this means:
- The asset’s energy supply must be fully disconnected.
- The release of stored energy must be prevented.
- All hazardous movements must have ceased.
- Physical, chemical, and biological hazards must be eliminated.
- Any unauthorized, accidental, or unexpected activation must be prevented.
To achieve this in practice, close coordination between maintenance and production is essential. Those responsible for resource planning must inform their counterparts in production planning and control about which measures will be carried out, when, and on which asset. Production must then take the necessary steps and update maintenance accordingly. Work clearance management, which defines and documents the appropriate processes, serves as the framework for this communication.
While IT is not strictly required to implement work clearance management, it can significantly enhance its efficiency and effectiveness.
Advantages of an IT solution:
- It describes the workflows that must be followed.
- It formalizes communication between all parties involved.
- It ensures a high level of transparency.
These benefits not only improve safety but also make decisions and actions traceable while promoting efficiency at multiple levels: The work clearance management process becomes faster, maintenance tasks are completed more quickly, and asset downtimes are minimized.
For companies using SAP ERP or SAP S/4HANA, SAP Work Clearance Management (SAP PM-WCM) is a useful tool in this context.
What is SAP PM-WCM?
SAP PM-WCM is a component of SAP Plant Maintenance (SAP PM) designed to control, monitor, and document the entire work clearance management process – including all required approvals. A key element is the WCM document, available in five forms:
- Work approval
- Work clearance application
- Additional request
- Operational work clearance document
- Standard work clearance document
Each WCM object can pass through multiple statuses, providing full transparency into the progress of the process.
Integration of SAP PM-WCM into the broader system landscape is essential, as effective work clearance management depends on smooth communication between all involved parties.
What are the benefits of SAP PM-WCM?
SAP PM-WCM ensures that work clearance management is executed reliably, significantly enhancing the safety of maintenance personnel. Beyond this primary goal, it delivers additional benefits:
- It guarantees full compliance with regulatory requirements and makes verification straightforward.
- It speeds up the entire work clearance management process while reducing administrative effort.
- It minimizes the downtime of the assets affected by work clearance.
Do you have questions about SAP PM-WCM?
Get in touch to learn how SAP PM-WCM can optimize your maintenance processes and boost safety, compliance, and efficiency.
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