Using Maintenance Strategy Plans

Using Maintenance Strategy Plans

Mark W. Scott

Vesta Partners LLC

[ Learning Points

Creating maintenance Strategies and Packages

Using maintenance strategies in Task Lists

How maintenance strategies are used in Maintenance Plans

Real Experience. Real Advantage. 2

[ Maintenance Strategies

Real Experience. Real Advantage.

[ Maintenance Strategy - Definition

A maintenance strategy defines the rules for the sequence andfrequency of maintenance activities. The strategy does not provideany details about the activity, object or date.

Maintenance strategies are assigned to a task list and also amaintenance plan. Task lists built with a maintenance strategy canonly be used on maintenance plans utilizing that same strategy –these are called strategy plans.


these are called strategy plans.

You create a maintenance strategy and strategy plans when you haveto perform maintenance activities that are based on each other orsupersede each other

Strategies contain maintenance packages which define the duration intime (e.g. weeks) or level of performance (e.g. operating hours) atwhich maintenance work is repeatedly performed. Therefore,strategies are used in both time-based and performance-basedmaintenance and represent the maintenance “cycle”.

[ Maintenance Strategy – Definition (continued)

Each strategy that is created should have a common unit ofmeasure (e.g. weeks, months, hours, miles) – you should nevermix the units of measure within a given strategy.

Maintenance packages are assigned to task list operations – anddefine the frequency and sequence in which task list operationswill appear as work order operations.


will appear as work order operations.

Maintenance packages are organized into a maintenancepackage hierarchy that determines which maintenancepackages are performed if several maintenance packages aredue at one time. The hierarchy can either be:

Single-level hierarchy

Multi-level hierarchy

[ Maintenance Strategy Terms

Strategy Code

Description

Scheduling Indicator (Type)

Strategy Unit

Call Horizon


Call Horizon

Shift Factor for Late Completion

Tolerance for Late Completion

Shift Factor for Early Completion

Tolerance for Early Completion

Factory Calendar

[Scheduling ParametersStrategyScheduling Type

Activity TypeActivity TypeActivity TypePackages

Settings can be established at the strategylevel and they will carry over to eachindividual maintenance plan when it iscreated.

Maintenance Strategy vs Scheduling Parameters


[ Comparing Maintenance Strategy to Plan

Strategy Field Changeable or Fixed in Plan

Scheduling Indicator (Type) Limited (can change between 3 typesof time based) (Cannot changebetween time based and performance)

Strategy Unit Fixed – No changes on Plan


Call Horizon Changeable on Plan

Shift Factors Changeable on Plan

Shift Tolerances Changeable on Plan

Factory Calendar Changeable on Plan (only on key dateand factory calendar plans)


Activity TypeActivity Type

Activity TypePackages

Scheduling Types•Time-Based

•E.g. – Every 30 calendar days

•Does NOT take into account the factory calendar

•Time-based by key date

•E.g. – Every 30 days do on the 28th of each month

Maintenance Strategy - Scheduling Type


•E.g. – Every 30 days do on the 28th of each month

•Time based – factory calendar

•E.g. – Every 30 working days, Option for seasonality

•Performance based

•E.g. – Every 100 Operating hours, 50,000 tons of coalthrough, xxxx units made, etc.



Scheduling Typeand Parametersdefined atStrategy Level

Strategies & Packages maintained within IP11

Maintenance Strategies & Packages (Cycles)


Time Based Strategy Packages

Performance Based StrategyPackages

Strategy Level



Settings can be established at the strategylevel and they will carry over to eachindividual maintenance plan when it iscreated.

Unit defines time basis on which schedulingcalculations are made. Use same Unitwithin a Strategy.

Once the strategy unit is created it can’t bechanged.

Maintenance Strategy – Unit of Measure




Call Horizon – Percent of the next cycle thesystem waits before the next call object is created

Call horizon determines when a maintenancecall object (e.g. Work Order, Notification) shouldbe generated. If the duration of the cycle is 360 days and the call

horizon is 0 %, 80%, or 100%, the system createsthe order after the following number ofdays:

• 0% -> Immediate call (order created 360 days

Maintenance Strategy – Call Horizon


• 0% -> Immediate call (order created 360 daysBEFORE plan date)

•80% -> Call after 288 days, that is 80% of 360days or creation of order 72 days before plan date.

•100% -> Call after 360 days, on the planned date(can work well if coordinated with IP30 Call Interval)

Call horizon is defined in percentage termson Strategy or individual Maintenance Plan

[Call Horizon – Example – Plan with 30 Day Cycle

100% HorizonCall & Plan Dates aresame

50% HorizonCall Date is 15 Daysbefore Plan

Scheduling ParametersStrategyScheduling Type


SAP Maintenance Strategy – Call Horizon


0% HorizonCall Date is 30 Daysbefore Plan

[Shift Factors & Tolerance

Tolerance defines the period within which late or early completion impacts subsequent scheduling of Plan. (+)Tolerance is set for late completion and (–) Tolerance for early completion.

If completion is within Tolerance period it is not considered late or early and does not impact schedule.

Cycle Cycle

Tolerance (+)(- )Tolerance

PlanDate

PlanDate

PlanDate



SAP Maintenance Strategy - Shift Factors / Tolerances


Tolerance (+)(- )Tolerance

30 Day

6 Day 6 Day

30 Day

If completion is out-with Tolerance period it will impact schedule taking account of Shift Factor values

Tolerance is defined as percentage ofcycle (for Strategy Plans it takes smallestperiod).

As shown here a 20% tolerance results in12 Day Tolerance window (6 Days oneither side of Planned Date).

[Shift Factors & Tolerance

The Shift Factor applies in event of late or early completion of Maintenance Task (Call Object).

It defines how much subsequent schedule dates will be changes as result of later or early completion.

Cycle Cycle

PlanDate

PlanDate

PlanDate

Early ActualCompletion

Late ActualCompletion



SAP Maintenance Strategy/Plan - Shift Factors/Tolerances


30 Day Cycle

8/1/2007

ActualCompletion8/24/2007

8/31/2007 9/30/2007

- 7 D

9/23/2007

- 7 D

OriginalPlanDate

NewPlanDate

100% Shift Factor, 20%Tolerance (6 days)

30 Day Cycle

8/1/2007


8/31/2007 9/30/2007

-6 D

OriginalPlanDate


No ChangeTo Plan Date

[

Shift Factors & Tolerance


Activity TypeActivity Type

Activity TypePackages

SAP Maintenance Strategy/Plan - Shift Factors/Tolerances


30 Day Cycle

8/1/2007


8/31/2007 9/30/2007

- 7 D

9/27/2007

- 3 D

OriginalPlanDate

NewPlanDate




• Cycle length

• Unit of Measure – same as strategy unit

•Cycle abbreviation

SAP Maintenance Strategy – Packages



Activity TypeActivity TypeActivity TypePackages Lead and Follow up Float

• Can only set on Strategy and not on individual Plans (not applicable to Single Cycle Plans).

• If change is made to float within Strategy you need to reassign Task List to Plan and RestartPlan schedule.

SAP Maintenance Strategy – Package Lead/Follow up Float


• The Initial (Lead) Float, defined in days, adjusts the Basic Start Date on Work Order.

• The Subsequent (Follow up) Float, defined in days, adjusts the Basic End Date on Work Order.

[Lead and Follow up Float - Example

Basic Start and End Dates oncalled Work Order reflect the Floatperiods



SAP Maintenance Plan - Package Lead / Follow up Float


-10+1

-10+2

[Multi-Level Hierarchy

Package Hierarchy value determinesplace in hierarchy and is used to controlpriority of packages with the same due(planned) date.

If packages with same due date are to



SAP Maintenance Plan – Package Hierarchies


If packages with same due date are tobe called then they must have samehierarchy number.

If packages have different hierarchynumbers then only the package withhighest number is called.

[Single-Level Hierarchy



SAP Maintenance Plan - Package Hierarchies


In this case 3M and 1Y arecalled with 1M.

[ Maintenance Strategy – Time w/Hierarchy Monthly Units

Hierarchies


Hierarchies

Advantages: Can coordinate single operation orders simplifying scheduling and time entry

Disadvantages: More text and duplicate text per operation

[ Maintenance Strategy – Time w/out /Hierarchy MonthlyUnits


[ Task List – Strategy Options with Same Results

Strategy w/Hierarchy Packages Only – Single package allocation

Strategy w/Hierarchy Packages Only - >1 package allocation

Above Model results in duplication of text



Strategy w/no hierarchies - >1 Package allocation

[ Strategies with and without Package Hierarchies

Packages without Hierarchy Packages with Hierarchy

It is possible to have strategies with packages that contain hierarchies and nohierarchies – This can be confusing.


Packages with and without Hierarchy

[

With this Offset both 3 Monthlyand Yearly packages will be



SAP Maintenance Plan – Packages – Package Offset


and Yearly packages will becalled 1st Cycle (Month)

With this Offset both Yearlypackage will be called 3rd Cycle(Month)

[

Package Offset



SAP Maintenance Plan – Package Offset


With this Offset 3Monthly will becalled 2nd Cycle and Yearly willbe called 3rd Cycle (Month)

[ Task List – Use in Preventive Maintenance


[ Task Lists - Supporting Maintenance Plans

Strategy Plans must

Task Lists applied in same way to Strategy, SingleCycle or Multiple Counter Plans


Strategy Plans musthave same Strategyon Task List, Itemsand Plans

Strategy plansMUST have a tasklist or will notschedule plan, willhave “Error”.

[ Task List – Assigning Packages

Strategy w/Hierarchy Packages Only – Single package allocation



Strategy w/no hierarchies - >1 Package allocation

[ Maintenance Strategy w/no Hierarchy


When work orders are then generated from the maintenance plans that use the task lists.The task list operations then become the work order operations. Because they are organizedin a single-level hierarchy, the operations will not supersede each other. In other words:

Operation 10 (check fluids) will come out every 2000 miles – even when Operation 20 (change oil)and Operation 30 (rotate tires) are also due

Operation 20 (change oil) will come out every 4000 miles – even when Operation 30 (rotate tires) isalso due

Operation 30 (rotate tires) will come out every 6000 miles – regardless of

other operations that are also due

[ Maintenance Strategy – w/Hierarchy


When work orders are then generated from the maintenance plans that use the task lists.The task list operations then become the work order operations. Because they are organizedin a multi-level hierarchy, the operations with a higher hierarchy number will alwayssupersede operations with a lower hierarchy number. In other words:

Operation 10 (check fluids) is due every 2000 miles, but it will only come out on the work orderwhen package 2 is the only one due

Operation 20 (check fluids, change oil) is due every 4000 miles. It will always supersede Operation10 because it has a higher hierarchy number.

Operation 30 (check fluids, change oil, rotate tires) is due every 6000 miles. It will always supersedeOperation 10 and Operation 20 because it has a higher hierarchy number.

[ Maintenance Plan – Types of Plans


[ Maintenance Plan – Strategy Plans – Time Based


[ Maintenance Plan – Strategy Plans – Time Based A time-based strategy plan should be used when:

Preventive maintenance activities are triggered when a certain time limitis reached

Maintenance activities (task list operations) change depending on thefrequency that is due – in other words, the maintenance activities arebased on each other or supersede each other

The time-based strategy plan consists of: Maintenance plan


Maintenance plan

Maintenance items (one or more)

Task list

Maintenance strategy

Task lists are required for time-based strategy plans

The strategy referenced on the maintenance plan must matchthe strategy used to build the task list attached to themaintenance items.

[ Maintenance Plan – Strategy Plans – Performance Based


[ Maintenance Plan – Strategy Plans – Performance Based A performance-based strategy plan should be used when:

Preventive maintenance activities are triggered by a counter reading

Maintenance activities (task list operations) change depending on the frequencythat is due – in other words, the maintenance activities are based on each otheror supersede each other

The time-based strategy plan consists of:

Maintenance plan

Maintenance items (one or more)

Task list


Task list

Maintenance strategy

Measuring point (counter)

Measurement documents (on-going transactional data)

Task lists are required for performance-based strategy plans

The strategy referenced on the maintenance plan must match the strategyused to build the task list attached to the maintenance items.

Readings must be taken on a consistent basis for the plan to functioncorrectly.

[ Preventive Maintenance – Performance Strategy no Hierarchy

Net operation count result:

Multiple operations per orderfor certain cycles.


When work orders are then generated from the maintenance plans that use the task lists.The task list operations then become the work order operations. Because they are organizedin a single-level hierarchy, the operations will not supersede each other. In other words:

Operation 10 (check fluids) will come out every 2000 miles – even when Operation 20 (change oil)and Operation 30 (rotate tires) are also due

Operation 20 (change oil) will come out every 4000 miles – even when Operation 30 (rotate tires) isalso due

Operation 30 (rotate tires) will come out every 6000 miles – regardless of other operations

that are also due

[ Preventive Maintenance – Performance Strategy with Hierarchy

Net operation count result:

Always single operation for allwork orders


When work orders are then generated from the maintenance plans that use the task lists. The task listoperations then become the work order operations. Because they are organized in a multi-levelhierarchy, the operations with a higher hierarchy number will always supersede operations with a lowerhierarchy number. In other words:

Operation 10 (check fluids) is due every 2000 miles, but it will only come out on the work order when package 2is the only one due

Operation 20 (check fluids, change oil) is due every 4000 miles. It will always supersede Operation 10 because ithas a higher hierarchy number.

Operation 30 (check fluids, change oil, rotate tires) is due every 6000 miles. It will always supersede Operation 10and Operation 20 because it has a higher hierarchy number.

[ Key Learnings

Creating maintenance Strategies and Packages

Using maintenance strategies in Task Lists

How maintenance strategies are used in Maintenance Plans


[

[

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Mark W. Scottmscott @vestapartners.com


[ SESSION CODE:

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Documents

Using Maintenance Strategy Plans