Tivoli Maximo Asset Management – Functional workshop Exercise - 007

Job Plans, Safety Plans,

Preventive Maintenance, Routes,
Meters, and Conditional Monitoring

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Job Plans

Introduction A job plan is a detailed description of the work tasks (operations), labor,
materials, and tools to be performed for a particular type of job. Use job
plans as templates for work order-specific work plans.

You use the Job Plans application to create, modify, or delete job plan
records. A job plan is a detailed description of work to be performed for a
work order. You can copy job plans to PM records, routes, and directly to
work orders. After a job plan becomes a work plan on a work order, you can
modify the work plan without affecting the job plan.

Job plans generally contain tasks (procedures), along with lists of estimated
labor, labor hours, materials, services, and tools required for the work. To
ensure that work on an asset is performed in a safe manner, you can add
work assets and associate safety plans that can be used when work is
performed.

Accessing Job This table shows you how to access the Job Plans application.
Plans

Step Action
1 From the Start Center, click Go To > Planning > Job Plans.

Result: The Job Plans application launches

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Job Plans, Continued

Tabs The Job Plans application is comprised of three tabs:

Tab Description
List Use any combination of fields to query and find records
matching the data in those fields.
Job Plan Create, modify, or delete a job plan record. This tab
displays basic information about the job plan, and
specifies job plan tasks and resources.
Work Assets Use to associate assets, locations, or items to the job
plan, as well corresponding safety plans. This tab also
allows you to specify whether to create a work order
when an item is purchased.
Specification To classify (or reclassify) a job plan and specify
attributes to define it further. For example, a job plan
might involve the classification of a pump, with
attributes of rpm, diameter, and speed, for which you
can define values. Attributes help to categorize job
plans, which makes it easier to find and manage job
plans.
Note: You also can classify a job plan on the Job Plan
tab, but to manage attributes for the job plan, use the
Specifications tab.
The Specifications tab also lets you specify attributes for
job plan tasks that you classify on the Job Plans tab.

Sub-tabs The Job Plan tab has four sub tabs: Labor, Materials, Services, Tools. Each
time you insert, delete or modify quantities or hours in the sub tab table
window, the cost fields update automatically.

Tab Description
Labor Maintains a list of labor and crafts for the job plan.

Materials Maintains a materials list for the job plan.

Services When you enter a service item that has a default
vendor, Maximo enters the default vendor and the unit
cost for the service.
Tools Maintains a tool list for the job plan.

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EXERCISE – 7.1

Creating a Job Follow these steps to create a Job Plan.

Plan

Step Action
1 Click the Insert New Job Plan button on the tool bar.

Result: a new record is created and displayed.

2 Complete the Job Plan Code and Description fields with the
following information:

Field Value
Job Plan JP-XX-MON
(where XX are your initials)
Description Monthly Inspection

3 Click the New Row button in the Job Plan tasks.

Result: A new tasks row detail is displayed with the Task number
defaulting to 10.
4 Enter a task to complete.

‘First steps to perform month overhaul’

5 Click the New Row button.

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6 Enter a second task to complete.

Result: Your screen should look similar to this:

7 Click Save.
8 Note that the task id’s getting generated in multiple of 10. It’s a
good practice to have taskid’s generated in this fashion which
allows addition of new steps in future if required in between of
existing 2 steps.

Planning When planning for Labor in a Job Plan you can plan for actual people or
Labor Crafts. Typically, you would plan for crafts since they tend to remain static
over time whereas people change.

Step Action
9 On the Labor sub-tab, click the New Row button.

Result: a new row opens in the labor sub tab.

10 Look up or enter a valid Craft.
e.g – Select ‘ELECT’ as one of the valid craft.

11 Enter the 2.25 hours in the Hours field.

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12 Optional: Repeat steps 2 and 3 for additional craft/labor

assignments. .
Add MECHANIC 1st Class as a 2nd craft and add hours as 1.5
hours. System will convert 1.5 hours to 1:30 [as 1 hour, 30
minutes]

13 Click Save.

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Planning for There are two buttons to plan materials for a Job Plan They are:
Materials • Select Spare Parts
• New Row

Step Action
14 Click the New Row button.

Result: the material detail line expands.

15 Add the following item: FIL-100 and VAL-500

Click NEW ROW and select item = FIL-100

Enter a valid Storeroom. [Central Store Room]

16 Add 2nd Item

Click NEW ROW and select item = VAL-500
Enter a valid Storeroom. [Central Store Room]

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17 Save the Job Plan.

Result: Your screen should look similar to this:

18 You can make use of task id to link the material/labor

requirement against the task as mentioned above.

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Services and The steps to plan for Services and Tools are similar to the steps covered
Tools already for labor and materials. For time purposes we will not cover them
now.

Work Assets The Work Assets tab lists locations, assets, and items associated with the
selected job plan. This table teaches you how to associate a Work Asset with
a Job Plan.

Step Action
19 On the Work Assets tab, click New Row. The Row Details open.
20 In the Location, Asset, or Item field, enter a value or click Detail
Menu to select an option and retrieve a value.

21 You can choose the location report [0560-XX] that you had created
in previous exercise.
22 Click ‘Save’ to save the Job Plan

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Activating Job A Job Plan’s status must be Active prior to being used in Work Order. When
Plan a job plan is created its default status is Draft and is considered Inactive.
Here you learn how to activate the Job Plan.

Step Action
23 Click Change Status tool bar button.

24 Click the New Status drop-down arrow.

25 Select Active.

26 Click OK.
27 Click Save.
Result: the Job Plan is now active and can be used in work orders.

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Using a Job Once created, Job Plans can be called by a work order on an as needed basis.
Plan When you call a Job Plan on the work order, the work order’s plan is
populated. By this method, Job Plans can be used over and over, whereas a
work plan is created one time for a single use.

We will create work order in later exercises. At that time we will make use of
this job plan.

EXERCISE – 7.2
Duplicating You can save time and effort when creating a number of job plans, especially
Job Plans when creating job plans for preventive maintenance.

Make use of this feature to create 2 additional job plans. One for quarterly
maintenance and one for yearly maintenance. Include some additional tasks
in quarterly and yearly maintenance job plans along with required labor,
tools, material and services.

Step Action
1 Go to Job Plans
2 Query for your Monthly Job Plan created earlier
3 Click Select Action > Duplicate Job Plan.

Result: A new job plan is created

4 Complete the Job Plan Code and Description fields with the
following information:

Field Value
Job Plan JP-XX-QTR
(where XX are your initials)
Description Quarterly Inspection

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5 Add two additional tasks. Be sure to label them as quarterly

tasks.

6 Modify the labor and materials to accommodate the additional

tasks.
7 Activate the Job Plan.
8 Repeat Steps 3-7 making an Annual Job Plan.
Result: When you complete this exercise you should have three
job plans:
• JP-xx-MON
• JP-xx-QTR
• JP-xx-ANN

We will use these 3 job plans with a PM [preventive maintenance

schedule] which would use first monthly job plan for 1st and 2nd
month, Quarterly job plan in 3rd month, again monthly job plan
for 4th and 5th month, Quarterly job plan for 6th month and so
on. Lastly, for 12th month, the annual job plan will be applied as
per the job schedule.

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Safety Plans

Introduction Safety Plans allow you to associate safety requirements and procedures with
work orders to fulfill regulatory requirements of agencies or government
entities. Safety Plans inform employees of hazards they might encounter
while performing work, as well as precautions they must take to prevent
accidents. The Safety Plans application is used to define those safety
procedures.

Safety Plans can be either generic safety plans for use on all work assets or
location, or for use when working on a particular work asset or location.
Safety Plans can also be used independently of locations or assets.

Accessing To get to the Safety Plans, follow the steps below

Safety Plans

Step Action
1a From the Start Center, click Go To > Planning> Safety > Safety
Plans.

Tabs There are five tabs in the Safety Plans application. They are explained here:

Tab Description
List Allows you to search Maximo for safety plans.

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Safety Plan Create safety plans, add and view work assets
associated with a selected safety plan.
Hazards and Add and view hazards associated with the selected
Precautions safety plan and view the precautions for those hazards
that you defined in the Safety Precautions application.
Hazardous Add and view hazardous materials associated with the
Materials selected safety plan.
Tag Outs Add and view hazards for work assets and tag out
procedures associated with each hazard.

EXERCISE – 7.3
Creating a Here you will create a safety plan and associate it with a location.
Safety Plan

Step Action
1 Click the Insert New Safety Plan icon.

Result: a new Safety Plan screen is displayed

2 Type the following:

Field Value
Safety Plan: SP-xx-01
Description: xx-On Site Safety Gear

Note: replace ‘xx’ with your initials.

3 Click the New Row button.

4 Enter or lookup a valid location. E.g. ‘0560-XX’

Result: Your screen should look similar to the screen here.

5 Click Save.

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Hazards and Next we add the hazards a worker can encounter and the precautions the
Precautions worker must take to mitigate the hazard.

Step Action
6 Click the Hazards and Precautions tab.
7 Click the New Row button.

8 Enter the following in the Hazard field: Noise, Heat, Dust, and
High Voltage

Result: the description for the hazard populates the field along
with the Precautions to take for the hazard selected.
9 Click Save.

Your screen should look similar to this:

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Going on from Your safety plan can now be associated with other Job Plans, Locations or
here Assets. Furthermore, this safety plan can be called when creating a work
order.
Let’s now attach this safety plan to the all three job plans that have been
created in previous exercise. JP-xx-Mon, JP-xx.Qtr, JP-xx-ANN

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Preventive Maintenance

Introduction Earlier in the Job Plans chapter you created three job plans. They were plans
for a monthly, quarterly, and an annual inspection. We will use those plans
during this chapter

EXERCISE – 7.4

Creating a PM Here you will create a Preventive Maintenance record.

Step Action
1 From the Start Center click Go To > Preventive Maintenance >
Preventive Maintenance.

2 Click Insert New PM.

3 Complete the following fields:

Field Value
Description Equipment PM Inspections
Asset AHU-100 [This is the same
asset that you had created in
previous exercise]

Note: Write your PM number here: _____________________

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4 Type JP-xx-MON in the Job Plan field. Where XX are your initials.

Note: You created and Activated three job plans in the last
chapter.
5 Click Save.

Result: Your screen should look similar to this:

Adding Next you will add the PM’s frequency.

Frequency

Step Action
6 Click the Frequency tab.
7 Complete the following:

Field Value
Frequency 1
Frequency Units MONTHS

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8 Click Save.
Result: Your screen should look similar to this.

Define ‘Estimated Next Due Date’ as today’s date.

Sequenced As your PM stands now, you have created a single PM that will generate WO
PMs every month. Next we will sequence the PMs to include quarterly and
annual inspections.

Step Action
9 Click on the Job Plan Sequence tab.

Result: Your screen should look like this:

10 Click on the New Row Button.

11 Type the quarterly job plan created in the last chapter:

JP-xx-QTR.

12 Type 3 in the Sequence field.

Note: when saved this means every third time this PM is

generated the Quarterly Job Plan will be used.

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13 Click on the New Row Button.

14 Type the Annual job plan created in the last chapter:

JP-xx-ANN.

15 Type 12 in the Sequence field.

Note: when saved this means every 12th time this PM is generated
the Annual Job Plan will be used.
16 Click Save.

View Job Plan The PM now calls for 3 different job plans, monthly, quarterly and annual.
Sequences Next, look at the sequence:

Step Action
17 Click Select Action > View Sequence.

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18 The Job Plan Sequence is displayed.

19 Change status of this PM to ‘Active’

20 You can now ‘test’ the sequence by generating work orders.

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21 Generate work orders using ‘Select Action’ for next 95+ days, and
check the job plans on the work orders. In this scenario, system
would create 4 work orders with first 2 monthly job plans, 3rd WO
with quarterly job plan, and 4th again with monthly job plan. ?

DO YOU KNOW WHY SYSTEM GENERATED 4 WO ?

Now, go to workorder application, and review all these

workorders.

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Routes

Introduction A route is a list of related work assets, which can be considered ‘stops’ along
the route. These route stops can be assets or locations, or a combination of
the two. A route can be a simple asset list. You can also create a route that
lists assets that are related by location, for example all of the servers in a
computer lab, or by type of asset, such as all fire extinguishers located
throughout the site. Routes simplify building hierarchies of work orders for
inspections.

You can use a route in the following ways:

Apply the route to a preventive maintenance record to generate inspection-

type work orders for all work assets listed as stops on the route.

Apply the route to a work order and generate child work orders for each
work asset listed as a stop on the route.

EXERCISE – 7.5

Creating a Here you will create a Route record.

Route

Step Action
1 From the Start Center click Go To > Planning > Routes.

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2 Click on the New Route Button.

3 Enter Route as ‘RU_NEW’

Click on ‘Select Locations’ and select all four ‘0560-XX locations’ as

created before.

Keep selected the first radio button option selected ‘Child work
orders’

4 Click OK and Save the record

5 Now, let’s apply this route to a PM and trigger-off the work
orders.

From the Start Center click Go To > Preventive Maintenance >

Preventive Maintenance.

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6 Click Insert New PM.

7
Enter details as below –

Description – PM using Routes RU_NEW

Route – RU_NEW

8 Click ‘Save’
Change Status of this PM to ‘Active’
Click ‘Select Action’
And Select ‘Generate Work Orders’

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9 Uncheck ‘Use Frequency Criteria’

Click ‘OK’
10 System will generate the total 4 workorders corresponding to each
location record which we had added in this ‘
Route’

Verify details of work orders.

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Meters
A meter record in Maximo is a virtual identifier used to record measurements. You
associate meter records with assets and locations to record measurements, for example
run hours, temperature, or pressure, that are used to track asset and location
performance. You use the Meters

Introductions Meters application allows to define a meter record along with the type of
meter, the unit of measure used by the meter, and the type of reading (delta
or actual) that the meter should record.
Meter records can be associated with assets, inventory items, and locations,
and can be used to drive condition monitoring and preventive maintenance.
Meters can be applied individually, or as part of a meter group.

Continuous . Meters where the readings increase continuously, for

example odometers. These meters might be used to track miles, hours,
engine starts, pieces produced, fuel consumed, and other continuous
readings.

Gauge . Meters where the readings may fluctuate, for example

thermometers or pressure gauges. These meters might be used to track
temperature, pressure, noise levels, oil levels, and other readings that
fluctuate.

Characteristic . Meters where an observed state is being tracked, for

example a color change. These meters might be used to track
Brick/Refractory Color (Yellow, orange, white), or oil color (Clear,
Turbid, Dark).

Step Action
1 From the Start Center click Go To > Assets > Meters

2 Click ‘New Meter’

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3 Enter details as below –

METER – TEMP-PUMP
Description – Temperature meter for Pump
Meter Type – Gauge
Unit of Measure – DEG-C

4 Save the record.

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Conditional Monitoring

Introduction Maximo uses measurement points as one possible criteria for generating PM
work orders. If a measurement is entered that reaches an upper or lower
action limit, a PM work order can be generated for the asset, either
automatically via a cron task, or manually via the Generate Work Order
action in the Condition Monitoring application.

You create measurement points in the Condition Monitoring application.

Each measurement point is associated with a meter. Meters are created in the
Meters application. When you create a measurement point for an asset
Maximo copies the measurement point to the Meters tab of the asset record.
You can record readings using the Enter Meter Readings and Manage Meter
Reading History actions available from the Select Action menu.

Step Action
1 From the Start Center click Go To > Assets > Conditional
Monitoring.

2 Click ‘New Measurement Point’ to create a new record

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3 Enter details as shown here,

ASSET – ‘AHU-100’ Lower Warning Limit – 45 C

METER – ‘TEMP-C’
Upper Warning Limit – 45 C
Upper Action Limit – 50 C
Upper Limit Job Plan – JP-XX-
MON
Lower Action Limit – 50 C
Lower Limit Job Plan – JP-
XX-MON

4 Save the record

5 Click ‘New Row’ on measurement section.

Enter first meter reading as ’24 C’.

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6 Click Select Action -> Generate Work Order

7 System will display the following message as meter reading 24 is

well within the range defined.

8 Now, enter a new meter reading as 52

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9 Repeat step 6-

Click Select Action -> Generate Work Order

10 This time, system will generate a workorder as new meter reading

[52 C] is outside the threshold limit.

11 Navigate to the meter now, and verify the assets, conditional

monitoring details.
This conditional monitoring feature can be used to monitor the
systems in a complete automated environment.

Let’s discuss some scenarios of it’s use in class.

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