Fundamentals of Preventive Maintenance Schedule Definition With Oracle eAM PDF

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 Page 2
The Fundamentals of Preventive Maintenance
Schedule Definition with Oracle eAM
Multiple Activity Preventive INTRODUCTION

Maintenance Schedule Definitions were This paper describes the Fundamentals of Preventive Maintenance (PM)
introduced in Release 12 of Oracle
Schedule Definition with Oracle Enterprise Asset Management (eAM). “You can
eAM.
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
1SeeOracle® Enterprise Asset Management, User's Guide, Release 12, September 2006, Page
2-112
.
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
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.
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
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.

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Other names may be trademarks of their respective owners.
•<Insert Picture Here>
EBS eAM Preventive Maintenance – An Introduction

What is a PM plan?
• 6months/every 5000 miles

Oil • Oil Filter, Oil
Change
• 2 years/30000 miles
Tune Up • Fuel filters, spark plugs etc.
• 45000 miles
Replace • Tires, Hydraulic Jack
Tires
Forecast the future work for the asset

4 Key Concepts –
9 Asset
9 Activity
9 BOM & Routing i.e Parts & Labor required to perform the activity
9 Rules
<Insert Picture Here>
Setup
PM Set
9 Groups a bunch of PM’s
9 Controls visibility at org/ global level
9 Useful for work planning
9 Every PM is assigned to a SET
PM Templates
9 Enable Planners to easily create PM’s for assets
9 PM gets instantiated upon asset creation
9 Can create templates for suppression
Definition
PM Definition
PM Activities, Cycles & Intervals
Cycle - 1 Cycle - 2
Oil Change Interval Count = 2 Oil Change Interval Count = 2
15000 30000 45000 60000
Interval 30000 Mile Interval 30000 Mile

Count = 1 Tune Up Count = 1 Tune Up
PM Examples
Assume – Last Service Date and Last Service Reading is the
EXAMPLE - 1
same as Last Reading Date and Last Meter Reading
Base Interval – 15000 miles Current Cycle – 3
Oil Change – 15000 miles, Repeat in Cycle = N Current Interval Count – 1
Interval Multiple - 1 Last Reading Date – 01-Oct – 2010
Tune Up – 30000 miles, Repeat in Cycle = N Last Meter Reading – 15000 miles
Interval Multiple - 2 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
EXAMPLE - 2
Interval Multiple - 1 Last Reading Date – 01-Oct – 2010
Tune Up – 30000 miles, Repeat in Cycle = N Last Meter Reading – 15000 miles
Interval Multiple - 2 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 Oil Change Oil Change

25 35
0 WO-Tune Up 28 WO-Tune Up 60
30
Tune Up
Manual/PM Work Orders in Planning status (Draft/Unreleased) that are NOT

firm can get rescheduled by the PM engine
PM Schedule Type
List •Eg:- Suggest a shutdown work order on Nov 25

•No computation; Look at Last Service Date and figure out the next
Dates suggestion
Date •Eg :- Suggest a work order every 7 days

•Look at Last Service Date and add a multiple of interval to Last
Based Service Date to get the next suggestion
Meter •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
Based •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 PM’s
9 Initial Reading, Reading Date, Rate and Number of Past Readings are used to
compute the Usage
9 Actual Meter Readings during work completion provide hints to the PM engine
for suggesting the next PM work order
9 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
Interval Multiple - 1 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 b) PM Work Order every 25 days
WO-1 WO-1
ASD-1 AED-3
SSD-0 SED-2 24 25 26 27 28 30
Actual StartActual End

Date to Date toNext
suggest suggest Next
Service Service
End Date Start Date
Base Date & Last Service Information
Rule – Suggest a work order every 25 days
WO-1(Comp) WO-3
Base Date
0 7 25
Last Service Date
Key Thoughts on Last Service Information

9Typically Last Service Information gets updated at work order completion
9Last Service Information is for an asset-activity
9If 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

Default • Can have multiple PM’s for the same asset
activity combination for simulation but only ONE
default PM
• Asset will run to failure and hence PM will not

Run to generate work orders unless you request explicitly
via “Include Run to Failure” flag in Forecast tab of
Failure Maintenance Workbench
Generate • Upon setting the flag to ‘YES’ only the next work
order for the PM schedule will be generated if the
Next Work other work orders for the same asset-activity are
in Complete/Cancelled status
Order • Reduces the clutter
Forecasting
PM Forecast – Maintenance Workbench
PM Forecasting – Generate WO program
High Level PM Logic
Summary
1. Get the asset

2. Find the list of PM’s for the
asset
3. For each PM fetch the
rules
4. Evaluate each rule and
generate the suggestions
5. Apply suppressions on the
suggested work orders
6. Add manual work orders
to the suggestions
7. Cancel the redundant work
orders
8. 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 S
A N S W E R S

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Fundamentals of Preventive

Maintenance Schedule Definition

Multiple Activity Preventive INTRODUCTION

TIME-BASED PM SCHEDULE DEFINITION FIXED DAY

Figure 1 Time-Based PM Schedule Definition Fixed Day

Figure 2 Forecast Work Orders Time-Based Fixed Day

TIME-BASED PM SCHEDULE DEFINITION FIXED INTERVAL

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

Figure 5 METER-BASED PM SCHEDULE DEFINITION FIXED METER

METER-BASED PM SCHEDULE DEFINITION FIXED INTERVAL

Figure 8 Forecast Meter-Based PM Schedule Definition Fixed Interval

Figure 9 Multiple Activity PM Schedule Definition Fixed Meter

Figure 10 - Preventive Maintenance (Schedule Definition)

Figure 11 Forecast Work Orders

TIME AND METER-BASED PM SCHEDULE DEFINITION

GENERATING PM WORK ORDERS BASED ON ABSOLUTE METER

Figure 13 - Forecast Work Orders

Figure 14 - Meter Definition

GENERATE NEXT WORK ORDER ONLY- METER BASED

Figure 17-Work Order Search

Figure 18 - Forecast Work

GENERATE NEXT WORK ORDER ONLY- DATE BASED

Figure 19 - PM Schedule Definition - Date Based

Figure 20-PM Cancelled Definition

Figure 21-Completion of Cancelled PM Work Order

For further information Contac

Copyright © 2007, Oracle. All rights reserved.

EBS eAM Preventive Maintenance – An Introduction

• 6months/every 5000 miles

Forecast the future work for the asset

Oil Change Interval Count = 2 Oil Change Interval Count = 2

15000 30000 45000 60000

Interval 30000 Mile Interval 30000 Mile

Oil Change Oil Change Oil Change

Manual/PM Work Orders in Planning status (Draft/Unreleased) that are NOT

List •Eg:- Suggest a shutdown work order on Nov 25

Date •Eg :- Suggest a work order every 7 days

Based Service Date to get the next suggestion

Meter •Suggest a work order every 10000 miles

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

No Manual Work Orders. When will the work orders be generated?

Next Suggested PM Date = 8-Sept-2010 + ((13000 + 15000) – 20000)/100

Actual StartActual End

Rule – Suggest a work order every 25 days

Last Service Date

Key Thoughts on Last Service Information

• PM will be used for work order generation

• Asset will run to failure and hence PM will not

1. Get the asset

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