Using Enterprise Asset Management Preventive Maintenance Oracle … · 2014-11-18 · Using Enterprise Asset Management Preventive Maintenance Venkatesh Hemmige Oracle Corporation

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


� 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


� 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


Generate work

orders

Complete WO

and PM cycle

EAM Preventive Maintenance – Key Set ups


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


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


� 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


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


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


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


• 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


� 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


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


� 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


� 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


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?



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


� Tune Up – 30000 miles , Repeat in Cycle = N

No Manual Work Orders.

What work orders are

generated?



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


– 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.


� 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


(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


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


� 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


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


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


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


� 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


� Using EAM PM and best practices

QUESTIONS

&


&

ANSWERS

Documents

Using Enterprise Asset Management Preventive Maintenance Oracle … · 2014-11-18 · Using Enterprise Asset Management Preventive Maintenance Venkatesh Hemmige Oracle Corporation