Fundamentals of Preventive Maintenance Schedule Definition With Oracle eAM

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



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 (Non-Serialized 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 .

Multiple Activity Preventive Maintenance Schedule Definitions were

introduced in Release 12 of Oracle eAM.


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


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.

Multiple Scheduling options are available, Base Date provides the best option for

maintaining a Fixed Interval


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


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.


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.


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


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.


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)


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.


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


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


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.


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.


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


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


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


BIBLIOGRAPHY

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

The Fundamentals of Reliability Centered Maintenance with Oracle eAM August 2008 For further information Contac Tom Sichko [email protected] (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?

Oil Change

• 6months/every 5000 miles• Oil Filter, Oil

Tune Up

• 2 years/30000 miles• Fuel filters, spark plugs etc.

Replace Tires

• 45000 miles• Tires, Hydraulic Jack

Forecast the future work for the asset 4 Key Concepts –

AssetActivityBOM & Routing i.e Parts & Labor required to perform the activityRules

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Setup

PM SetGroups a bunch of PM’s Controls visibility at org/ global levelUseful for work planningEvery PM is assigned to a SET

PM TemplatesEnable Planners to easily create PM’s for assetsPM gets instantiated upon asset creationCan create templates for suppression


Definition

PM Definition

PM Activities, Cycles & Intervals

Oil Change

30000 Mile Tune Up

Oil Change

30000 Mile Tune Up

15000 30000 45000 60000

Cycle - 1 Cycle - 2

Interval Count = 1

Interval Count = 1

Interval Count = 2Interval Count = 2

PM Examples

Base Interval – 15000 milesOil Change – 15000 miles, Repeat in Cycle = N

Interval Multiple - 1Tune Up – 30000 miles, Repeat in Cycle = N

Interval Multiple - 2

Current Cycle – 3 Current Interval Count – 1 Last Reading Date – 01-Oct – 2010Last Meter Reading – 15000 miles Usage – 500 miles/day

No Manual Work Orders. What work orders are generated?

31st Oct 2010 – Tune Up 30th November 2010 – Oil Change 30th December 2010 – Tune Up

No Manual Work Orders. What work orders are generated?

31st Oct 2010 – Oil Change 30th November 2010 – Tune Up 30th December 2010 – Oil Change

EXAMPLE - 1

EXAMPLE - 2Base Interval – 15000 milesOil Change – 15000 miles, Repeat in Cycle = N

Interval Multiple - 1Tune Up – 30000 miles, Repeat in Cycle = N


Current Cycle – 3 Current Interval Count – 0 Last Reading Date – 01-Oct – 2010Last Meter Reading – 15000 miles Usage – 500 miles/day

Assume – Last Service Date and Last Service Reading is the same as Last Reading Date and Last Meter Reading

Suppression, Tolerance & Manual Work Orders

030

60

Oil Change Oil Change Oil Change

Tune Up

Tolerance – 5 days

28WO-Tune Up WO-Tune Up

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

25 35

SUPPRESSIONTOLERANCE Oil Change – Every 30 DaysTune Up – Every 60 Days

PM Schedule Type

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

List Dates

•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

Date Based

•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

Meter Based

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

Meter Setup for Meter Based PM’sInitial 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 orderIf 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

Base Interval – 15000 milesOil Change – 15000 miles, Repeat in Cycle = N


Current Cycle – 3 Current Interval Count – 0 Last Service Date – 01-Jul – 2010 Last Service Reading – 13000Usage – 100 miles/day

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

EXAMPLE - 3

Odometer – AscendingNo Reset, AdjustmentMeter Readings :-5-Aug – 2010 175008- Sept-2010 20000

Last Service Information

a) Work Order – Duration of 2 Day

SSD-0 SED-2

ASD-1 AED-3

b) PM Work Order every 25 days

EXAMPLE - 4

2625 27 28

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

WO-1

24 30

WO-1

Base Date & Last Service Information

250

Base Date

7

WO-1(Comp)

Rule – Suggest a work order every 25 days

WO-3

Last Service Date

Key Thoughts on Last Service InformationTypically Last Service Information gets updated at work order completionLast Service Information is for an asset-activityIf a PM has suppressions, Last Service Information stamps the date for the activity

on the Master PM and its suppressed activities

Other Key Concepts

• 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

Default

• 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

Run to Failure

• 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

Generate Next Work

Order


Forecasting

PM Forecast – Maintenance Workbench

PM Forecasting – Generate WO program

High Level PM LogicSummary

1. Get the asset2. Find the list of PM’s for the

asset3. For each PM fetch the

rules4. Evaluate each rule and

generate the suggestions5. Apply suppressions on the

suggested work orders6. Add manual work orders

to the suggestions7. Cancel the redundant work

orders8. Combine the entire list and

generate a consolidated suggestion

9. For Generate WO program, call the WO API to create and schedule the work orders

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

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