Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM

An Oracle White Paper September 2010

The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM

Introduction ....................................................................................................... 3 Time-Based PM Schedule Definition Fixed Day ......................................... 4 Time-Based PM Schedule Definition Fixed Interval ................................... 5 Meter-Based PM Schedule Definition Fixed Meter ..................................... 7 Meter-Based PM Schedule Definition Fixed Interval .................................. 8 Multiple Activity PM Schedule Definition Fixed Meter ............................ 10 Time and Meter-Based PM Schedule Definition ........................................ 12 Generating PM Work Orders based on absolute Meter Interval ............. 13 Generate Next Work Order Only- Meter Based ........................................ 16 Generate Next Work Order Only- Date Based .......................................... 18 Cancelling a Preventive Maintenance Work Order .................................... 19 Bibliography ..................................................................................................... 20

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The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM

Multiple Activity Preventive Maintenance Schedule Definitions were introduced in Release 12 of Oracle eAM.

INTRODUCTION

This paper describes the Fundamentals of Preventive Maintenance (PM) Schedule Definition with Oracle Enterprise Asset Management (eAM). You can create a Preventive Maintenance Schedule Definition on an Asset Group (NonSerialized Rebuildable)/Activity combination, Asset Number/Activity combination, or an Asset Route/Activity combination. 1 Oracle eAM introduced the concept of Multiple Activity PM Schedule definition with Release 12. The ability to define multiple activities for a PM Schedule Definition enhanced the relationships between activities, allowing a user to define and control multiple activities from one form. This paper will define some common and complex PM Schedule Definitions, including the following: Time-Based PM Schedule Definition Fixed Days Repeat on same number of days without regard to when last PM Work Order was completed, for example a Safety Inspection every Monday Time-Based PM Schedule Definition Fixed Interval Repeat on the exact number of days since the last PM Work Order was completed Meter-Based PM Schedule Definition Fixed Meter Repeat on same number of hours without regard to when last PM Work Order was completed, for example if a PM Work Order was completed late, 550 hours instead of 500 hours, the next work order would be generated at 750 hours for a PM Schedule Definition defined at an interval of 250 Hours Meter-Based PM Schedule Definition Fixed Interval Maintain a fixed interval between PMs, for example if a PM Work Order was completed late, 550 hours instead of 500 hours, the next work order

1See

Oracle Enterprise Asset Management, User's Guide, Release 12, September 2006, Page 2-112 .

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would be generated at 800 hours for a PM Schedule Definition defined at an interval of 250 Hours Multiple Activity PM Schedule Definition Fixed Meter The multiple activity PM schedule definition allows the user to define a PM schedule set for maintaining an asset, defining multiple activities and then allowing the system to maintain the scheduling relationship between the activities. Additionally, this definition addresses; Intervals per Cycle, Current Cycle, Current Interval Count and Base Interval. Time and Meter-Based PM Schedule Definition The asset should not go more than 7 days without a PM Work Order even if the meter interval has not been met.

TIME-BASED PM SCHEDULE DEFINITION FIXED DAY

The Time-Based Schedule Definition Fixed Day illustrates a PM Schedule Definition that generates a PM Work Order the same number of days every week, month or year from a Base Date. Figure 1 illustrates the PM Schedule Definition.

Figure 1 Time-Based PM Schedule Definition Fixed Day

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Multiple Scheduling options are available, Base Date provides the best option for maintaining a Fixed Interval

For Scheduling Options the Base Date of 14-JUL-2008 (Base Date Count (BDC), in combination with Base Interval in Days of 7 will generate a PM Work Order every 7 days from 14-JUL-2008. In this example, the PM Work Order is generated every Monday. Figure 2 illustrates a simulation of PM Work Orders for the next 60 days.

Figure 2 Forecast Work Orders Time-Based Fixed Day

TIME-BASED PM SCHEDULE DEFINITION FIXED INTERVAL

The Time-Based Schedule Definition Fixed Interval illustrates a PM Schedule Definition that generates a PM Work Order the same number of days since the last PM Work Order was completed. Figure 3 illustrates the PM Schedule Definition.

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Figure 3 Time Based PM Schedule Definition Fixed Interval For Scheduling Options the Actual End Date in combination with Base Interval in Days of 30 will generate a PM Work Order 30 days from the completion of the prior PM Work Order. In this example, the PM Work Order is generated 30 days from the completion of the prior PM Work Order. Figure 4 illustrates a simulation of PM Work Orders for the next 180 days.

Figure 4 Forecast Work Orders Time-Based PM Schedule Definition Fixed Interval

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METER-BASED PM SCHEDULE DEFINITION FIXED METER

The Meter-Based Schedule Definition Fixed Meter illustrates a PM Schedule Definition that generates a PM Work Order the same number of hours, miles, and units from a base date without regard to the completion of the PM Work Order. Figure 5 illustrates the PM Schedule Definition.

Figure 5 METER-BASED PM SCHEDULE DEFINITION FIXED METER In the above example, the PM Schedule Definition will create a PM Work Order based on 24 hours of operation without regard to the completion of the pervious PM Work Order. If the PM Work is completed at 26 hours of operation, the next PM work order will be generated at 48 hours of operation. The Scheduling Option of Base Meter is used in combination with a Base Interval of 24. Figure 6 illustrates a simulation of PM Work Orders for the next 30 days.

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Figure 6 Forecast Meter-Based PM Schedule Definition Fixed Meter METER-BASED PM SCHEDULE DEFINITION FIXED INTERVAL

The Meter PM Schedule Definition Fixed Interval illustrates a PM Schedule Definition that generates a PM Work Order the same number of hours, miles and units since the last PM Work Order was completed., maintaining a fixed interval between PMs, for example if a PM Work Order was completed late, 550 hours instead of 500 hours, the next work order would be generated at 800 hours for a PM Schedule Definition defined at an interval of 250 Hours.

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Figure 7 PM Schedule Definition Fixed Interval For Scheduling Options the Actual End Date in combination with Base Interval of 10 hours of operation. In this example, the PM Work Order will be generated 10 hours from the completion of the prior PM Work Order.

Figure 8 Forecast Meter-Based PM Schedule Definition Fixed Interval

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MULTIPLE ACTIVITY PM SCHEDULE DEFINITION FIXED METER

The Multiple Activity PM Schedule Definition Fixed Meter illustrates a PM Schedule Definition that allows a user to define multiple PM activities on a single PM Schedule Definition, the definition generates a PM Work Order the same number of hours, miles, and units from a base meter without regard to the completion of the PM Work Order. The definition will address the following; Intervals per Cycle, Current Cycle, Current Interval Count and Base Interval.

Figure 9 Multiple Activity PM Schedule Definition Fixed Meter Figure 9 illustrates the definition of a Multiple Activity PM Schedule Definition. The preventive maintenance requirements for the conveyor include an Inspection for every 100 hours of operation, a Minor PM for every 200 hours of operation and a Major PM for every 400 hours of operation. The Inspection Activity occurs every 100 hours; all other activities are a multiple of 100 hours, 100 hours is defined as the Base Interval.

In the above example Base Meter was selected as the Scheduling Option, you will need to enter the meter name and define the scheduling starting point (to the right of the meter), in this example 0. This field is known as the Base Meter Count (BMC) and starts the forecast count off, in conjunction with the defined Cycle and Cycle Interval Count (CIC). The BMC, Cycle and Current Interval Count (CIC) must be synchronised. The program will define values for; Intervals per Cycle, Current Cycle and Current Interval Count, Current Cycle and Current Interval Count will be updated when a Work Order is completed.

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Enter the required activities; the Activity Inspection is scheduled after 100 hours of operation (Interval Multiple (1) x Base Interval (100)). The Activity Minor PM is scheduled after 200 hours of operation, and the Activity Major PM is scheduled after 400 hours of operation. Repeat in Cycle determines if an activity can occur multiple times during a cycle, in this example the Inspection can occur multiple times within the cycle, the Minor PM will not be planned at the 400 hour interval. The Meter Name is then entered in the with a Base Interval of 100, press Save, the program provides default values for the following; the Intervals per Cycle (4), Current Cycle (1) and Current Interval Count (0). The program will update Current Cycle and Current Interval Count when PM Work Orders are completed. For example at 210 hours of operation, two Inspection Work Orders and one Minor PM Work Order have been generated and completed. The Current Interval Count has been updated to (2). The Current Interval Count provides a count within the Current Cycle, the Current Interval Count is updated to (1) with the start of each new cycle. The Current Cycle provides a count of the number of times a PM Set (Inspection, Minor PM and Major PM) has been completed. In the example below, the Current Cycle remains (1), the Current Cycle will be updated to (2) with the completion of the PM Set and the start of a new cycle.

Figure 10 - Preventive Maintenance (Schedule Definition)

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When forecasting work orders for the next 30 days, note that the activity Minor PM is not included in the forecast but the Activity Inspection is included, the Repeat in Cycle controls if an activity will occur within a Cycle. For the activity Inspection the Repeat in Cycle is Yes, for the activity Minor PM the Repeat in Cycle is No, the Minor PM will be generated once per cycle.

Figure 11 Forecast Work Orders

TIME AND METER-BASED PM SCHEDULE DEFINITION

The Time and Meter-Based Schedule Definition illustrates a PM Schedule Definition that will generate a PM Work Order based on either time or a meter reading. The asset should not go more than 7 days without a PM Work Order even if the meter interval has not been met. The purpose this PM Schedule Definition to ensure that an asset is inspected when an asset's meter readings fall below the expected usage. Figure 12 illustrates the PM Schedule Definition.

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Figure 12 PM Schedule Definition Date & Meter In the above definition both a Date and Meter Rule is defined, the program will generate a PM Work Order when the meter reading exceeds 100 hours of operation or after 7 days. GENERATING PM WORK ORDERS BASED ON ABSOLUTE METER INTERVAL

The Forecast Work Orders and Generate Work Orders programs base the forecast and creation of work orders for meter-based preventive maintenance schedules on the Usage Rate and the Number of Past Readings. For example, if a user defines a usage rate of 8 Hours per Day for a meter and then forecasts PM work order for a 200 hour PM, the program will forecast a work order 25 days

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from run date, see Figure 13.

Figure 13 - Forecast Work Orders Since the PM engine uses the meter usage rate to calculate the PM recommendations within the forcast horizon, work orders could be created early (before the meter interval exceeded) or late. In some cases it may be desired that the PM work orders are required to be created only when the meters actually clock the PM interval defined in the PM schedule definition. To accommodate such meter driven PM requirements, changes were made to the Forecast Work Orders and Generate PM Work Orders programs in Release 11.5.10 and later applied to the Release 12. These changes will prevent the early and late creation of work orders and create PM work orders only when the meter has indeed crossed the defined PM intervals. Such work orders would be implemented with a work order Scheduled Start date as the system date when the PM forecast was initiated. Figure 14 illustrates a Meter Definition that will prevent an early or late creation of a work order.

Figure 14 - Meter Definition With the Rate per Day defined as less than or equal to 1 and the Number of Past Readings exceeding 999999, the Forecast Work Orders and Generate PM Work Orders programs will not create a work order until the

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absolute meter reading has been exceeded. An additional setup includes a definition within Enterprise Asset Management Parameters to not implement from the horizon date but to include past dates; this will ensure that the system takes into consideration all potential work orders.

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Figure 15 - Enterprise Asset Management Parameters

GENERATE NEXT WORK ORDER ONLY- METER BASED

Generate Next Work allows a user to define if the system creates a new work order if the previous/active work .order is in draft, unreleased, released or hold status. When option is defined as Yes, the system will not create a new work order if a work order is active, when option is defined as No the system will create a new work order if a work order is active. It is important to note that this option only applicable for the concurrent program Create Work Orders and not the on-line program Forecast Work see Figure 16.

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Figure 16 PM Schedule Definition - Meter Based Entering a meter reading of 2.1 hours and submitting concurrent program Create Work Orders, creates a work order to inspect the atomizer. Entering subsequent meter readings of 4.2, 6.3 and 8 hours and submitting concurrent program Create Work Order Orders, does not create a new work order to inspect atomizer. See Figure 17.

Figure 17-Work Order Search

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Note this option Next Work Order is not applicable when Forecasting Work from Maintenance Workbench. See Figure 18.

Figure 18 - Forecast Work GENERATE NEXT WORK ORDER ONLY- DATE BASED

Generate Next Work allows a user to define if the system creates a new work order if the previous/active work .order is in draft, unreleased, released or hold status. When option is defined as Yes, the system will not create a new work order if a work order is active, when option is defined as No the system will create a new work order if a work order is active. It is important to note that this option only applicable for the concurrent program Generate Work Orders and not the on-line program Forecast Work. Figure 19 illustrates the Preventive Maintenance (Schedule Definition) for Date Based PM Schedule.

Figure 19 - PM Schedule Definition - Date Based

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CANCELLING A PREVENTIVE MAINTENANCE WORK ORDER

When cancelling a preventive maintenance work order the recommended process is to complete the work order, if the work order is cancelled the concurrent program Generate Work Orders could create a replacement work order. Figure 20 illustrates the setup of work order statuses for PM Cancelled. A work order status of PM Cancelled was created with an associated system status of Complete No Charges.

Figure 20-PM Cancelled Definition

Figure 21 illustrates the completion of a cancelled preventive maintenance work order.

Figure 21-Completion of Cancelled PM Work Order

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BIBLIOGRAPHY

Oracle Enterprise Asset Management, User's Guide, Release 12, September 2006.

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The Fundamentals of Reliability Centered Maintenance with Oracle eAM August 2008

For further information Contac Tom Sichko Thomas.Sichko@Oracle.com (720) 308-1498 Oracle Corporation World Headquarters 500 Oracle Parkway Redwood Shores, CA 94065 U.S.A. Worldwide Inquiries: Phone: +1.650.506.7000 Fax: +1.650.506.7200 oracle.com Copyright 2007, Oracle. All rights reserved. This document is provided for information purposes only and the contents hereof are subject to change without notice. This document is not warranted to be error-free, nor subject to any other warranties or conditions, whether expressed orally or implied in law, including implied warranties and conditions of merchantability or fitness for a particular purpose. We specifically disclaim any liability with respect to this document and no contractual obligations are formed either directly or indirectly by this document. This document may not be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without our prior written permission. Oracle is a registered trademark of Oracle Corporation and/or its affiliates. Other names may be trademarks of their respective owners.

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EBS eAM Preventive Maintenance An Introduction

What is a PM plan?
6months/every 5000 miles Oil Filter, Oil 2 years/30000 miles Fuel filters, spark plugs etc. 45000 miles Tires, Hydraulic Jack

Oil Change

Tune Up

Replace Tires

Forecast the future work for the asset

4 Key Concepts Asset Activity BOM & Routing i.e Parts & Labor required to perform the activity Rules

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Setup

PM Set
Groups a bunch of PMs Controls visibility at org/ global level Useful for work planning Every PM is assigned to a SET

PM Templates
Enable Planners to easily create PMs for assets PM gets instantiated upon asset creation Can create templates for suppression

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Definition

PM Definition

PM Activities, Cycles & Intervals

Cycle - 1

Cycle - 2 Interval Count = 2

Oil Change
15000 Interval Count = 1

Oil Change
45000 Interval Count = 1

Interval Count = 2

30000

60000

30000 Mile Tune Up

30000 Mile Tune Up

PM Examples
EXAMPLE - 1
Assume Last Service Date and Last Service Reading is the same as Last Reading Date and Last Meter Reading Current Cycle 3 Current Interval Count 1 Last Reading Date 01-Oct 2010 Last Meter Reading 15000 miles Usage 500 miles/day 30th December 2010 Tune Up Base Interval 15000 miles Oil Change 15000 miles, Repeat in Cycle = N Interval Multiple - 1 Tune Up 30000 miles, Repeat in Cycle = N Interval Multiple - 2 31st Oct 2010 Tune Up

No Manual Work Orders. What work orders are generated? 30th November 2010 Oil Change

EXAMPLE - 2
Base Interval 15000 miles Oil Change 15000 miles, Repeat in Cycle = N Interval Multiple - 1 Tune Up 30000 miles, Repeat in Cycle = N Interval Multiple - 2 Current Cycle 3 Current Interval Count 0 Last Reading Date 01-Oct 2010 Last Meter Reading 15000 miles Usage 500 miles/day

No Manual Work Orders. What work orders are generated? 31st Oct 2010 Oil Change 30th November 2010 Tune Up 30th December 2010 Oil Change

Suppression, Tolerance & Manual Work Orders

TOLERANCE SUPPRESSION
Oil Change Every 30 Days Tune Up Every 60 Days

Tolerance 5 days Oil Change 25 0 WO-Tune Up 28 WO-Tune Up 30 Tune Up Oil Change 35 60 Oil Change

Manual/PM Work Orders in Planning status (Draft/Unreleased) that are NOT firm can get rescheduled by the PM engine

PM Schedule Type

List Dates Date Based Meter Based

Eg:- Suggest a shutdown work order on Nov 25 No computation; Look at Last Service Date and figure out the next suggestion

Eg :- 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

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

PM can be List Dates or Rule Based (Date Based/Meter Based)

Meter Setup for Meter Based PMs

Initial Reading, Reading Date, Rate and Number of Past Readings are used to compute the Usage Actual Meter Readings during work completion provide hints to the PM engine for suggesting the next PM work order If Rate (per day) <= 1 and Number of Past Readings > 999999 then the PM program will not create a work order until the absolute meter reading when the next PM is due (Also check Implement from Horizon in eAM parameters)

PM Examples with Meter Readings

EXAMPLE - 3
Base Interval 15000 miles Oil Change 15000 miles, Repeat in Cycle = N Interval Multiple - 1 Current Cycle 3 Current Interval Count 0 Last Service Date 01-Jul 2010 Last Service Reading 13000 Usage 100 miles/day

Odometer Ascending No Reset, Adjustment Meter Readings :5-Aug 2010 17500 8- Sept-2010 20000 No Manual Work Orders. When will the work orders be generated?

Next Suggested PM Date = 8-Sept-2010 + ((13000 + 15000) 20000)/100 = 8-Sept-2010 + 80 days = 27th November, 2010

Last Service Information

EXAMPLE - 4
a) Work Order Duration of 2 Day ASD-1 AED-3 b) PM Work Order every 25 days WO-1 WO-1

SSD-0

SED-2

24

25

26

27

28

30

Actual End Date Next Service End Date Actual Start Date to suggestto suggest Next Service Start Date

Base Date & Last Service Information

Rule Suggest a work order every 25 days

Base Date

WO-1(Comp)

WO-3

7 Last Service Date

25

Key Thoughts on Last Service Information Typically Last Service Information gets updated at work order completion Last Service Information is for an asset-activity If a PM has suppressions, Last Service Information stamps the date for the activity on the Master PM and its suppressed activities

Other Key Concepts

Default
PM will be used for work order generation Can have multiple PMs for the same asset activity combination for simulation but only ONE default PM

Run to Failure Generate Next Work Order

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

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 Reduces the clutter

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Forecasting

PM Forecast Maintenance Workbench

PM Forecasting Generate WO program

High Level PM Logic

Summary
1. 2. 3. 4. 5. 6. 7. 8. Get the asset Find the list of PMs for the asset For each PM fetch the rules Evaluate each rule and generate the suggestions Apply suppressions on the suggested work orders Add manual work orders to the suggestions Cancel the redundant work orders Combine the entire list and generate a consolidated suggestion For Generate WO program, call the WO API to create and schedule the work orders

9.

Q U E S T I O N S A N S W E R S