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Using Enterprise Asset Management Preventive .pdf
1.
Using Enterprise Asset
Management Preventive Maintenance Venkatesh Hemmige Oracle Corporation
2.
The following is
intended to outline our general product direction. It is intended for information purposes only, and may not be incorporated into any contract. It is not a commitment to deliver any material, code, or functionality, and should not be relied upon Safe Harbor Statement Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 2 any material, code, or functionality, and should not be relied upon in making purchasing decision. The development, release, and timing of any features or functionality described for Oracle’s products remains at the sole discretion of Oracle.
3.
Agenda An overview
of Preventive Maintenance Key Set ups to make Preventive Maintenance work Walking through a functional flow case for PM Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 3 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 QA
4.
Overview Why preventive
maintenance Prevent expenditures in terms of work time losses, downtime impacts, opportunities lost etc Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 4 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.
5.
The steps of
a complete PM Cycle Define PM schedules with rules Define suppression if any Define Assets, activities, meters Associate activities and assets with meter Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 5 Generate work orders Complete WO and PM cycle
6.
EAM Preventive Maintenance
– Key Set ups Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 6
7.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 7 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
8.
Meters Meters need
to be defined separately and associated with an asset or asset group Meters – Absolute and Change types Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 8 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
9.
Meter definition Copyright ©
2014, Oracle and/or its affiliates. All rights reserved. 9
10.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 10 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
11.
Set names Copyright ©
2014, Oracle and/or its affiliates. All rights reserved. 11
12.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 12 • 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
13.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 13 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
14.
Last Service Information Copyright
© 2014, Oracle and/or its affiliates. All rights reserved. 14
15.
Other important 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 - Asset will run to failure and hence PM will not generate work Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 15 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
16.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 16 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
17.
Activities, Cycles and
Intervals Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 17
18.
Example Base Interval
– 15000 miles Oil Change – 15000 miles, Repeat in Cycle = N Interval Multiple - 1 Tune Up – 30000 miles , Repeat in Cycle = N No Manual Work Orders. What work orders are generated? Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 18 Interval Multiple - 2 Current Cycle – 3 Current Interval Count – 0 Last Reading Date – 01-Oct – 2014 Last Meter Reading – 15000 miles Usage – 500 miles/day 31st Oct 2014 – Oil Change 30th November 2014 – Tune Up 30th December 2014 – Oil Change
19.
Example Base Interval
– 15000 miles Oil Change – 15000 miles, Repeat in Cycle = N Interval Multiple - 1 Tune Up – 30000 miles , Repeat in Cycle = N No Manual Work Orders. What work orders are generated? Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 19 Interval Multiple - 2 Current Cycle – 3 Current Interval Count – 1 Last Reading Date – 01-Oct – 2014 Last Meter Reading – 15000 miles Usage – 500 miles/day 31st Oct 2014 – Tune Up 30th November 2014 – Oil Change 30th December 2014 – Tune Up
20.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 20 – 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
21.
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. Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 21 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’
22.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 22 (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……..
23.
Base Date option Base Date WO-1(Comp) Rule
– Suggest a work order every 25 days WO-2 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 23 25 0 Date 7 Last Service Date
24.
PM Work Orders
generation – two options Maintenance Workbench A flexible option that allows viewing asset work orders and also has simulation capabilities Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 24 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
25.
The Maintenance Workbench Copyright
© 2014, Oracle and/or its affiliates. All rights reserved. 25
26.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 26 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.
27.
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 Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 27 CSI_COUNTER_ASSOCIATIONS Contains the Asset Meter Association CSI_COUNTERS_B Meters/Meter Template table Generate Preventive Maintenance Work Orders The executable is EAMPMSDU
28.
Best practices Focus
preventive maintenance effort on critical assets High Number of Repair and emergency Work Orders High Maintenance Cost Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 28 High Maintenance Cost High Maintenance Man-hours For setting up preventive maintenance use should be made of the equipment manufacturer’s recommendations (available in user guides, technical manuals etc)
29.
Summary Need for
Preventive Maintenance Setting up and planning for PM Using EAM PM and best practices What we covered Copyright © 2014, Oracle and/or its affiliates. All rights reserved. 29 Using EAM PM and best practices
30.
QUESTIONS Copyright © 2014,
Oracle and/or its affiliates. All rights reserved. 30 ANSWERS
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