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Fundamentals of Preventive Maintenance Schedule Definition With Oracle eAM

Fundamentals of Preventive Maintenance Schedule Definition With Oracle eAM

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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 

The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM

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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 .

The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM

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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

The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM

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In this example. 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. 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.Multiple Scheduling options are available. Figure 3 illustrates the PM Schedule Definition. Figure 2 illustrates a simulation of PM Work Orders for the next 60 days. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 5 . the PM Work Order is generated every Monday.

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. In this example.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. Figure 4 Forecast Work Orders Time-Based PM Schedule Definition Fixed Interval The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 6 .

miles. Figure 6 illustrates a simulation of PM Work Orders for the next 30 days. the next PM work order will be generated at 48 hours of operation.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. If the PM Work is completed at 26 hours of operation. and units from a base date without regard to the completion of the PM Work Order. 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. Figure 5 illustrates the PM Schedule Definition. Figure 5 METER-BASED PM SCHEDULE DEFINITION FIXED METER In the above example. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 7 . The Scheduling Option of Base Meter is used in combination with a Base Interval of 24.

miles and units since the last PM Work Order was completed. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 8 .. the next work order would be generated at 800 hours for a PM Schedule Definition defined at an interval of 250 Hours. 550 hours instead of 500 hours. for example if a PM Work Order was completed late. maintaining a fixed interval between PMs.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.

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. Figure 8 Forecast Meter-Based PM Schedule Definition Fixed Interval The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 9 . the PM Work Order will be generated 10 hours from the completion of the prior PM Work Order.

the definition generates a PM Work Order the same number of hours. 100 hours is defined as the Base Interval. The definition will address the following. Intervals per Cycle. The preventive maintenance requirements for the conveyor include an Inspection for every 100 hours of operation. Current Cycle. Current Cycle and Current Interval Count. and units from a base meter without regard to the completion of the PM Work Order. in conjunction with the defined Cycle and Cycle Interval Count (CIC).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. Intervals per Cycle. all other activities are a multiple of 100 hours. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 10 . The BMC. Figure 9 Multiple Activity PM Schedule Definition Fixed Meter Figure 9 illustrates the definition of a Multiple Activity PM Schedule Definition. This field is known as the Base Meter Count (BMC) and starts the forecast count off. in this example 0. Current Interval Count and Base Interval. a Minor PM for every 200 hours of operation and a Major PM for every 400 hours of operation. The program will define values for. miles. Cycle and Current Interval Count (CIC) must be synchronised. The Inspection Activity occurs every 100 hours. In the above example “Base Meter” was selected as the Scheduling Option. Current Cycle and Current Interval Count will be updated when a Work Order is completed. you will need to enter the meter name and define the scheduling starting point (to the right of the meter).

For example at 210 hours of operation. The Activity “Minor PM” is scheduled after 200 hours of operation. The program will update Current Cycle and Current Interval Count when PM Work Orders are completed. press “Save”. 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 Intervals per Cycle (4). The Meter Name is then entered in the with a “Base Interval’ of 100. The Current Interval Count has been updated to (2). 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.Enter the required activities. The Current Cycle provides a count of the number of times a PM Set (Inspection. the Current Cycle will be updated to (2) with the completion of the PM Set and the start of a new cycle.Preventive Maintenance (Schedule Definition) The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 11 . Figure 10 . In the example below. the program provides default values for the following. two Inspection Work Orders and one Minor PM Work Order have been generated and completed. Current Cycle (1) and Current Interval Count (0). the Current Cycle remains (1). and the Activity “Major PM” is scheduled after 400 hours of operation. the Activity “Inspection” is scheduled after 100 hours of operation (Interval Multiple (1) x Base Interval (100)). Minor PM and Major PM) has been completed.

The purpose this PM Schedule Definition to ensure that an asset is inspected when an asset's meter readings fall below the expected usage. For the activity “Inspection” the Repeat in Cycle is “Yes”. 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.When forecasting work orders for the next 30 days. Figure 12 illustrates the 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. note that the activity “Minor PM” is not included in the forecast but the Activity “Inspection” is included. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 12 . the “Minor PM” will be generated once per cycle. the “Repeat in Cycle” controls if an activity will occur within a Cycle. for the activity “Minor PM” the Repeat in Cycle is “No”.

the program will generate a PM Work Order when the meter reading exceeds 100 hours of operation or after 7 days. For example. the program will forecast a work order 25 days The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 13 .Figure 12 PM Schedule Definition Date & Meter In the above definition both a Date and Meter Rule is defined. 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. 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”.

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. 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. see Figure 13. work orders could be created early (before the meter interval exceeded) or late. Such work orders would be implemented with a work order Scheduled Start date as the system date when the PM forecast was initiated. Figure 13 . the “Forecast Work Orders” and “Generate PM Work Orders” programs will not create a work order until the The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 14 .10 and later applied to the Release 12.5. Figure 14 illustrates a Meter Definition that will prevent an early or late creation of a work order.Meter Definition With the “Rate per Day” defined as less than or equal to “1” and the “Number of Past Readings” exceeding 999999. changes were made to the “Forecast Work Orders” and “Generate PM Work Orders” programs in Release 11.from run date. To accommodate such meter driven PM requirements. Figure 14 .Forecast Work Orders Since the PM engine uses the meter usage rate to calculate the PM recommendations within the forcast horizon.

this will ensure that the system takes into consideration all potential work orders. An additional setup includes a definition within “Enterprise Asset Management Parameters” to not implement from the horizon date but to include past dates.absolute meter reading has been exceeded. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 15 .

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. released or hold status.order is in draft. the system will not create a new work order if a work order is active. When option is defined as “Yes”.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 . The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 16 . unreleased.

1 hours and submitting concurrent program “Create Work Orders”. Entering subsequent meter readings of 4.2.Meter Based Entering a meter reading of 2. Figure 17-Work Order Search The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 17 . creates a work order to inspect the atomizer.3 and 8 hours and submitting concurrent program “Create Work Order Orders”. See Figure 17.Figure 16 –PM Schedule Definition . does not create a new work order to inspect atomizer. 6.

when option is defined as “No” the system will create a new work order if a work order is active. When option is defined as “Yes”.Note this option “Next Work Order” is not applicable when “Forecasting Work” from Maintenance Workbench. the system will not create a new work order if a work order is active. Figure 19 illustrates the Preventive Maintenance (Schedule Definition) for Date Based PM Schedule.order is in draft. unreleased. Figure 19 . 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”.PM Schedule Definition .DATE BASED “Generate Next Work” allows a user to define if the system creates a new work order if the previous/active work .Date Based The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 18 .Forecast Work GENERATE NEXT WORK ORDER ONLY. released or hold status. Figure 18 . See Figure 18.

if the work order is cancelled the concurrent program “Generate Work Orders” could create a replacement work order. Figure 21-Completion of Cancelled PM Work Order The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 19 . Figure 20 illustrates the setup of work order statuses for “PM Cancelled”. Figure 20-PM Cancelled Definition Figure 21 illustrates the completion of a cancelled preventive maintenance work order. A work order status of “PM Cancelled” was created with an associated system status of “Complete – No Charges”.CANCELLING A PREVENTIVE MAINTENANCE WORK ORDER When cancelling a preventive maintenance work order the recommended process is to complete the work order.

BIBLIOGRAPHY Oracle® Enterprise Asset Management. Release 12. September 2006. The Fundamentals of Preventive Maintenance Schedule Definition with Oracle eAM Page 20 . User's Guide.

Other names may be trademarks of their respective owners.7200 oracle.506. without our prior written permission. electronic or mechanical. CA 94065 U. including implied warranties and conditions of merchantability or fitness for a particular purpose.com Copyright © 2007.506.Sichko@Oracle.650.650. .com (720) 308-1498 Oracle Corporation World Headquarters 500 Oracle Parkway Redwood Shores. Worldwide Inquiries: Phone: +1. for any purpose.S. This document is provided for information purposes only and the contents hereof are subject to change without notice.A.7000 Fax: +1. All rights reserved.The Fundamentals of Reliability Centered Maintenance with Oracle eAM August 2008 For further information Contac Tom Sichko Thomas. nor subject to any other warranties or conditions. whether expressed orally or implied in law. This document may not be reproduced or transmitted in any form or by any means. Oracle. 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 is not warranted to be error-free. Oracle is a registered trademark of Oracle Corporation and/or its affiliates.

•<Insert Picture Here> EBS eAM Preventive Maintenance – An Introduction .

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. Oil • 2 years/30000 miles • Fuel filters.What is a PM plan? • 6months/every 5000 miles • Oil Filter.e Parts & Labor required to perform the activity Rules .

<Insert Picture Here> Setup .

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

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

<Insert Picture Here> Definition .

PM Definition .

1 Cycle .PM Activities. Cycles & Intervals 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 .

2 Base Interval – 15000 miles Oil Change – 15000 miles. What work orders are generated? 31st Oct 2010 – Oil Change 30th November 2010 – Tune Up 30th December 2010 – Oil Change .1 Tune Up – 30000 miles.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. What work orders are generated? 30th November 2010 – Oil Change EXAMPLE . Repeat in Cycle = N Interval Multiple . Repeat in Cycle = N Interval Multiple .2 31st Oct 2010 – Tune Up No Manual Work Orders.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. Repeat in Cycle = N Interval Multiple .1 Tune Up – 30000 miles. Repeat in Cycle = N Interval Multiple .PM Examples EXAMPLE .

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 .

Suggest a shutdown work order on Nov 25 •No computation. Last Meter Reading and Last Service Reading. 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. 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) .PM Schedule Type List Dates Date Based Meter Based •Eg:.

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) .Meter Setup for Meter Based PM’s Initial Reading.

2010 .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 8.3 Base Interval – 15000 miles Oil Change – 15000 miles.PM Examples with Meter Readings EXAMPLE . Repeat in Cycle = N Interval Multiple . 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.Sept-2010 20000 No Manual Work Orders.

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 .Last Service Information EXAMPLE .

Base Date & Last Service Information Rule – Suggest a work order every 25 days Base Date WO-1(Comp) WO-3 0 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 PM’s 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 .

<Insert Picture Here> Forecasting .

PM Forecast – Maintenance Workbench .

PM Forecasting – Generate WO program .

call the WO API to create and schedule the work orders 9. 5. 4. 8.High Level PM Logic Summary 1. Get the asset Find the list of PM’s 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. . 6. 2. 3. 7.

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

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