using enterprise asset management preventive maintenance oracle … · 2014-11-18 · using...
TRANSCRIPT
Using Enterprise Asset Management Preventive
Maintenance
Venkatesh Hemmige
Oracle Corporation
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Agenda
� An overview of Preventive Maintenance
� Key Set ups to make Preventive Maintenance work
� Walking through a functional flow case for PM
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� Walking through a functional flow case for PM
� A brief description on the PM engine, tables and programs that are relevant
� Best practices and tips while using EAM PM
� Q&A
Overview
� Why preventive maintenance
� Prevent expenditures in terms of work time losses, downtime impacts,
opportunities lost etc
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� Maintain the equipment in optimum working condition
� Scope of preventive maintenance also includes replacement of various
equipments
� The potential consequences of breakdown in operation can exceed service
costs several times over.
The steps of a complete PM Cycle
Define PM
schedules with
rules
Define
suppression if
any
Define Assets,
activities,
meters
Associate
activities and
assets with
meter
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Generate work
orders
Complete WO
and PM cycle
EAM Preventive Maintenance – Key Set ups
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Assets and Activities
� Assets – Capital or Rebuildable.
� Rebuildable assets - can be installed, removed and refurbished.
� Activity – is a ‘template’ that carries information on resources required and
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materials used
� Meters are used to measure asset usage and service the asset, based on the
measurement.
� Associate asset or asset group with activities and meters
Meters
� Meters need to be defined separately and associated with an asset or asset
group
� Meters – Absolute and Change types
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� Meter usage based on ‘Rate per day’ or ‘Number of Past Readings’
� Can define meter hierarchies so that flow from parent to child meter
� Meter reset
� Meter readings can be entered directly or upon completion of work orders
Meter definition
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Set Names in PM
• A PM schedule for an Activity and an Asset Number or Asset Group must
uniquely belong to a Set Name
• Multiple PM Schedules for the same Asset Number or Asset Group and
Activity combination are created across Sets
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Activity combination are created across Sets
• However, out of those PM Schedules, one can be identified as the Default and
used for generating Work Orders. Other PM Schedules in other Sets can be
used for simulation purposes
• Can assign PM schedules to set MAIN. This is the seeded set name that
already exists
Set names
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PM Schedule Definition
• Define the required PM scheduling rules
• PM uses Meter ‘Rate per day’ or ‘Number of Past Readings’ to arrive at future
dates.
• Enter Last Service Information (dates). These dates are used by the Preventive
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• Enter Last Service Information (dates). These dates are used by the Preventive
Maintenance Scheduler as a starting point for calculating the next due date for
a suggested Work Order.
• After the Preventive Maintenance Work Order is completed this date resets to
the completion date
• Can use suppression to prevent activity repetition
PM Rules� List Dates – ex: Suggest a shutdown work order on Nov 25
– No computation; Look at Last Service Date and figure out the next suggestion
� Date Based – ex: Suggest a work order every 7 days
– Look at Last Service Date and add a multiple of interval to Last Service Date to
get the next suggestion
� Meter Based – ex: Suggest a work order every 10000 miles
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� Meter Based – ex: Suggest a work order every 10000 miles
– Look at Last Meter Reading Date, Last Meter Reading and Last Service Reading;
Figure out the usage based on meter setup/moving average and calculate the next
Service Date
– If number of meter readings > Number of Past Readings in Meter definition use
Moving Average
Last Service Information
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Other important concepts
� Default - PM will be used for work order generation. Can have multiple PM’s
for the same asset activity combination for simulation but only ONE default
PM
� Run to Failure - Asset will run to failure and hence PM will not generate work
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� Run to Failure - Asset will run to failure and hence PM will not generate work
orders unless you request explicitly via “Include Run to Failure” flag in
Forecast tab of Maintenance Workbench
� Generate Next Work Order - Upon setting the flag to ‘YES’ only the next
work order for the PM schedule will be generated if the other work orders for
the same asset-activity are in Complete/Cancelled status
Defining a Multiple Activity PM
� Define basic details for PM schedule and enter the multiple activities that need
to be planned and scheduled
� Define the Rule type that needs to be used. There are three types: Date Rules,
Meter Rules and List dates
� Define Base interval such that it maps to the individual activity durations
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� Define Base interval such that it maps to the individual activity durations
� Define Intervals per cycle such that it maps to the activity with maximum time
duration
� Then ‘fit in’ the other activities using ‘Interval Multiple’ and ‘Repeat in Cycle’
fields
Activities, Cycles and Intervals
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Example
� Base Interval – 15000 miles
� Oil Change – 15000 miles, Repeat in Cycle = N
� Interval Multiple - 1
� Tune Up – 30000 miles , Repeat in Cycle = N
No Manual Work Orders.
What work orders are
generated?
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� Interval Multiple - 2
Current Cycle – 3
Current Interval Count – 0
Last Reading Date – 01-Oct – 2014
Last Meter Reading – 15000 miles
Usage – 500 miles/day
31st Oct 2014 – Oil Change
30th November 2014 – Tune Up
30th December 2014 – Oil Change
Example
� Base Interval – 15000 miles
� Oil Change – 15000 miles, Repeat in Cycle = N
� Interval Multiple - 1
� Tune Up – 30000 miles , Repeat in Cycle = N
No Manual Work Orders.
What work orders are
generated?
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� Interval Multiple - 2
Current Cycle – 3
Current Interval Count – 1
Last Reading Date – 01-Oct – 2014
Last Meter Reading – 15000 miles
Usage – 500 miles/day
31st Oct 2014 – Tune Up
30th November 2014 – Oil Change
30th December 2014 – Tune Up
Multiple Activity PM for an Automobile
� A typical application would be for an automobile where usage is measured by
an odometer.
� We need to perform the following activities on a Car:
– An Oil change every 1000 Km
– A general maintenance check every 5000 Km
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– A general maintenance check every 5000 Km
– A thorough Brake maintenance every 15000 km
� Define the Assets, Activities and the Meter.
� Meter will be of absolute ascending type
� Associate the activities and the meter to the asset
� We are now ready to create a PM schedule
PM for an Asset Car
� Set the Base Interval to the value of activity with minimum duration – Oil
change every 1000 Km
� Now the activity with maximum time duration is Brake maintenance at 15000
Km. Hence the number of intervals in the cycle = 15000/1000 = 15
� Interval multiple decides when maintenance is performed for each activity.
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� Interval multiple decides when maintenance is performed for each activity.
Activity duration = Interval multiple x Base Interval. For a general
maintenance check every 5000 km this will be 5 x 1000.
� If you need an activity to be repeated within a cycle choose ‘Yes’
PM Engine calculations
� PM Engine calculates the work order due dates by a 3 step process:
� Due reading = last service reading + interval = 0 + 5000 = 5000
� Days remaining for next PM = (due reading- latest reading)/usage rate =
(5000-0)/100 = 50, at usage rate of 100
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(5000-0)/100 = 50, at usage rate of 100
� 1st due date = latest date + left days
= 05/18/2014 + 50
= 07/07/2014 (cycle, sequence =1,1) and so on……..
Base Date option
Base
Date
WO-1(Comp)
Rule – Suggest a work order every 25 days
WO-2
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250
Date
7
Last Service Date
PM Work Orders generation – two options
� Maintenance Workbench
A flexible option that allows viewing asset work orders and also has
simulation capabilities
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� Generate Work Orders CP
Program can be used to generate PM work orders on a number of
Asset/Activities for a given cut off date
The Maintenance Workbench
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PM – Important Tables and what they contain
Table Name Description
EAM_PM_SCHEDULINGS Stores the details of Preventive
Maintenance schedules.
EAM_PM_ACTIVITIES Stores the activities for a PM Schedule
and their associated attributes
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and their associated attributes
MTL_EAM_ASSET_ACTIVITIES This table stores association between
Assets and Asset Activities.
EAM_PM_SCHEDULING_RULES Stores the rules of each preventive
maintenance schedule.
PM – Important Tables and what they contain
Table Name Description
CSI_COUNTER_READINGS Holds the historical readings of a counter
instance or a meter instance.
CSI_COUNTER_ASSOCIATIONS Contains the Asset Meter Association
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CSI_COUNTER_ASSOCIATIONS Contains the Asset Meter Association
CSI_COUNTERS_B Meters/Meter Template table
Generate Preventive Maintenance
Work Orders
The executable is EAMPMSDU
Best practices
� Focus preventive maintenance effort on critical assets
� High Number of Repair and emergency Work Orders
� High Maintenance Cost
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� High Maintenance Cost
� High Maintenance Man-hours
� For setting up preventive maintenance use should be made of the equipment
manufacturer’s recommendations (available in user guides, technical manuals
etc)
Summary
� Need for Preventive Maintenance
� Setting up and planning for PM
� Using EAM PM and best practices
What we covered
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� Using EAM PM and best practices
QUESTIONS
&
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&
ANSWERS