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

A brief description on the PM engine, tables and programs that are relevant

Best practices and tips while using EAM PM

Q&A

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 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.

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 The steps of a complete PM Cycle

Associate
Define Assets, Define PM Define
activities and
activities, schedules with suppression if
assets with
meters rules any
meter

Complete WO Generate work

and PM cycle orders

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 EAM Preventive Maintenance Key Set ups

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 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

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 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

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 Meter definition

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 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
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

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 Set names

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 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
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

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 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
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

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 Last Service Information

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 Other important 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 - 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

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 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 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

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 Activities, Cycles and Intervals

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 Example

Base Interval 15000 miles No Manual Work Orders.

What work orders are

Oil Change 15000 miles, Repeat in Cycle = N generated?

Interval Multiple - 1

Tune Up 30000 miles , Repeat in Cycle = N

Interval Multiple - 2
Current Cycle 3
Current Interval Count 0 31st Oct 2014 Oil Change
Last Reading Date 01-Oct 2014 30th November 2014 Tune Up
Last Meter Reading 15000 miles 30th December 2014 Oil Change
Usage 500 miles/day

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 Example

Base Interval 15000 miles No Manual Work Orders.

What work orders are

Oil Change 15000 miles, Repeat in Cycle = N generated?

Interval Multiple - 1

Tune Up 30000 miles , Repeat in Cycle = N

Interval Multiple - 2
Current Cycle 3
Current Interval Count 1 31st Oct 2014 Tune Up
Last Reading Date 01-Oct 2014 30th November 2014 Oil Change
Last Meter Reading 15000 miles 30th December 2014 Tune Up
Usage 500 miles/day

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 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 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

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 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.
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

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 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

1st due date = latest date + left days
= 05/18/2014 + 50
= 07/07/2014 (cycle, sequence =1,1) and so on..

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 Base Date option
Rule Suggest a work order every 25 days

WO-1(Comp) WO-2
Base
Date
0 7 25
Last Service Date

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 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

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 The Maintenance Workbench

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 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

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.

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 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_COUNTERS_B Meters/Meter Template table

Generate Preventive Maintenance The executable is EAMPMSDU

Work Orders

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 Best practices

Focus preventive maintenance effort on critical assets

High Number of Repair and emergency Work Orders

High Maintenance Cost

High Maintenance Man-hours

For setting up preventive maintenance use should be made of the equipment
manufacturers recommendations (available in user guides, technical manuals
etc)

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 Summary
What we covered

Need for Preventive Maintenance

Setting up and planning for PM

Using EAM PM and best practices

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 QUESTIONS
&
ANSWERS
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