Oracle_SCM_Maintenance_TipsNTricks.pdf

Copyright © 2019, Oracle and/or its affiliates. All rights reserved. |
SCM – Implementing Maintenance
Programs
Rick Dorsey, Product Management
Jeff Plachta, Strategy
July 25, 2019
Tips and Best Practices

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Program Agenda
Introduction to Maintenance Cloud
Maintenance Program Overview
Installed Base Asset Enabled for Maintenance
Work Definition Modeling and Setup
Work Requirement Modeling and Setup
Forecast Use Cases
1
2
3
4
5
5
6

Introduction to Maintenance Cloud
6

• Enabling efficient and productive maintenance operations
Maintenance Cloud Features
Repair
Plan Optimize
Manage
Asset Definition
Manage Work
Orders
Work Definition
and Planning
Manage work
areas, work
centers, resources
Work order
costing
Update / complete
Work orders
Analyze Performance
Asset Management Maintenance Cost Management
Inventory
Oracle Confidential – Internal/Restricted/Highly Restricted 7
Maintain-to-Optimize Flow
Maintenance
Programs

Maintenance Cloud Vision

Prescriptive Maintenance
Relies on information provided by predictive methods to identify problems
and identify root cause of failure.
Goal: Identify problems and isolate the source of the failure.
Predictive Maintenance
Equipment condition rather than time intervals
determines the need for service.
Goal: correct the problem before the equipment actually
fails can save time and money and avoid downtime and
repair costs.
Reactive Maintenance
Oldest maintenance approach
Goal: Equipment isn’t repaired until its broken.
Leads to costly downtime, higher maintenance
costs, safety hazards.
Preventive Maintenance
Time-based or planned maintenance.
Goal: Maintain equipment in a healthy condition.
Wasteful, may lead to over servicing or under
servicing, higher inventory costs.

Maintenance Program
Overview
9

Maintenance Program
Overview
• Maintenance Programs are used to define and generate the daily
preventative maintenance forecast for one or more Assets in the
Maintenance Cloud
– The forecast is then used as the basis for creating preventative maintenance Work
Orders, thereby reducing the work load for maintenance planners, allowing them to
focus on maintenance program auditing, optimization and exception-based events
• Maintenance Programs are generally based on an OEM (Original Equipment
Manufacturer) service manual or similar
– Therefore Work Definition setup and modeling will drive the forecast
• Manually created maintenance Work Orders can be created, but they will
not have any impact on the forecast
10

Maintenance Program
Overview
• Maintenance Programs are created and maintained in the context of each
individual Maintenance Organization
– Therefore, Assets which will be managed through a Program must be associated as
operating in the same Organization
• Additionally, Assets may have utilization Meters defined, which may be
used to create a Meter-based forecast
11

Installed Base Asset
12
Enabled for Maintenance

Assets must be created and enabled for
maintenance in order to be forecasted by a
Maintenance Program and have Work
Orders created.
Operating Organization – inventory
organization in which the Asset is created
and is expected to be operated and
maintained. This is the organization in which
a Forecast can be generated.
Maintenance Organization – this icon will
render a list of related Maintenance-enabled
Organizations for the Asset where manually
created Work Orders can be created.
13
Install Base Asset

Maintainable Asset Flag:
• Renamed Allow maintenance programs
• When set to Y, the Asset can be selected
for forecasting in a Maintenance Program
• When set to N, the Asset will not be
available for forecasting in a
Maintenance Program
Allow work orders:
• When set to Y, the Asset can have
maintenance Work Orders created, either
manually or by using a Maintenance
Program
• When set to N, the Asset will not be
available for the creation of Work Orders
14
Install Base Asset

Base Utilization Rate per Day (Daily
Rate) - the expected daily utilization
rate per Meter, not per Asset.
If the checkbox Allow meter to
schedule a maintenance program = Y,
then this Meter can be used to
forecast a Work Requirement in a
Maintenance Program.
For example, if set to 50 Miles per
day, then a forecast where
maintenance is due every 3000 miles
would result in the due dates every
60 days.
Meter recording during Work Order
completion can be helpful to
increment the forecast
15
Install Base Asset
Utilization Meters

Work Definition
Modeling and Setup
16

Work Definition
Overview
• A maintenance Work Definition represents the operations, operation items,
and resources needed for a maintenance or repair process
– When translating a service interval into a Work Definition, a user will review the
originating service tasks and determine how Work Definitions should be defined into
a unique and logical sequence of steps
• A user would decide how to model their Work Definitions:
– Unique Work Definitions
– Incremental Work Definitions
– “Add-on” Work Definitions
17

Work Definition
Example – Unique Work Definition
• “Every 5000 miles, the engine oil
and filter require replacement”
• Create a unique definition:
– Operation Steps:
• 10: Perform general inspection of vehicle
undercarriage
– Resource: Technician .25 hour
– Item: none
• 20: Drain engine oil into capture container
– Item: none
• 30: Remove and replace oil filter
– Item: Oil Filter
• 40: Refill engine oil to capacity
– Item: Engine Oil 10w-40
• 50: Run engine to operating temperature and
perform leak check
– Item: none
18

Work Definition
Example – Incremental Work Definition
• “Every 10,000 miles, the engine oil
and filter and engine air cleaner
element requires replacement”
• Create an Incremental Definition:
– Operation Steps:
• 10: Perform general inspection of vehicle
undercarriage
– Item: none
• 20: Drain engine oil into capture container
– Item: none
• 30: Remove and replace oil filter
– Item: Oil Filter
• 40: Refill engine oil to capacity
– Item: Engine Oil 10w-40
• 50: Remove and replace the engine air cleaner
element
– Item: Air Cleaner Element
• 60: Run engine to operating temperature and
perform leak check
– Item: none
19

Work Definition
Example – “Add-on” Work Definition
• “Every 10000 miles, the engine air cleaner element requires replacement”
– Incremental Step:
• 10: Remove and replace engine air cleaner element
– Item: Air Cleaner Element
• This Work Definition would be expected to be Merged with a unique Work
Definition during the creation of a Work Order
20

Work Requirement
Modeling and Setup
21

Work Requirement
Overview
• A Maintenance Program is made up of one or more Work Requirements
• Work Requirements are usually created for each service interval task for an
Asset, or even a group of related service interval tasks, based on:
– An Asset or a group of Assets by common Item
– A common Calendar and/or Meter based forecast
– One or more Work Definitions with Operation Steps
• This includes unique, incremental and add-on
• It is expected that each Work Requirement will create a single Work Order
for each due date in the forecast for each applicable Asset
– There is a 2-step process: Forecast, then create Work Orders
22

Intuitive UI walks the users
through the process of
selecting an Asset or Item,
the methods used for
generating a forecast and
then defining what work is
required and how often it
should occur.
Work Requirements include
capabilities such as
forecasting by a Calendar
Pattern, Utilization Meter or
using both methods with a
“whichever comes first” rule.
23
Work Requirement
Setup

Work Requirement
Forecasting using a Calendar on a Cycle
• A forecast is assumed to be created using a Cycle based on a number of
user-defined Intervals:
– Each Interval is incremented by a Calendar or utilization Meter
– Work Definitions may or may not be due on each Interval
– Intervals can overlap, providing Suppress and Merging of Work Definitions
• If a forecast just repeats each interval, then a cycle is not needed
– Work Definitions will be due each time the forecast iterates
24

Work Requirement
Suppress and Merge during Forecasting using a Cycle
25
• Work Definitions are due
either at every interval in a
Cycle or at only certain
Intervals in a Cycle
• If the definitions overlap on
the same interval, the
Suppress/Merge options are
taken into consideration
– Suppress – lower interval Work
Definition(s) are ignored
– Merge – all Work Definitions are
merged
• One Work Order is created
per due date

Work Requirement
Forecasting using a Meter
26
• Meter forecasts can be used
with or without a Cycle
• Meters are forecasted based
on:
– Meter Start Date or last Meter
Reading in history < sysdate
– Daily Rate
– Base Interval
– Next calculation Method
• Estimate Daily Interval = Base
Interval / Daily Rate,
providing an estimated
duration of each iteration in
a forecast

Work Requirement
Forecasting using a Calendar and a Meter
27
• Forecasts can also compete
between Calendar and
Meters
• Based on a rule of
“whichever comes first”, the
system will then Suppress the
losing method’s forecasted
due dates
• It can be quite difficult for
there to be a competing
forecast between Calendar
Patterns and Meters, but
between Multiple Meters can
be useful

Forecast
Use Cases
28

Use Case 1
Setup
• Requirement: The HVAC systems in a user’s facility typically require that
the intake filters be changed every 1 month
– Therefore, they wish to setup a Calendar-based forecast to forecast and accomplish
the removal and replacement of the filters by HVAC unit
• Solution Approach:
– Create a Work Definition for the HVAC Filter change
– Create a maintainable Asset for each HVAC unit that will need to have its filters
changed
– Create a new Maintenance Program, with an Item-based Work Requirement for the
filter changes, using a Calendar-based forecast
29

Use Case 1
Work Requirement
30
• Define a Cycle-based
forecast, with 12 intervals, as
each interval will represent 1
month in a year.
• Use a start date of 1-Jan,
however, the first forecasted
due date > Sysdate.
– The system will consider the start
date in the forecasted cycle of
intervals.
• Override the suppress Merge
header level attributes, as we
will be replicating the same
Calendar Pattern across Work
Requirements for the same
Assets.

Use Case 1
Work Requirement
31
• Add the Work Definition and
ensure that is repeats on
every interval of the cycle
• Run the Forecast for the
Maintenance Program. View
the forecast in the Gantt
Chart
• Adjust the chart to show a
time frame and use the zoom
out to show by month
• Note that the first due is
August 5th for each of the
HVAC Assets (interval 8) and
then there are subsequent
due dates per month

Use Case 2
Setup
• Requirement: The HVAC system in a user’s facility typically requires that
the intake filters be changed every 3 months
– However, due to seasonal pollen, they wish to change the filters more often during
certain months, like April and May. Therefore, they wish to setup a “custom”
Calendar-based forecast to accommodate this requirement.
– Create a Work Definition for the HVAC Filter change
changed
32

Use Case 2
Work Requirement
33
• Use the same Forecasting
methods from Use Case 1
• Add the Work Definition and
ensure that is repeats on every 3
intervals of the cycle, then add
again for interval 4 and 5
• Run the Forecast for the
Maintenance Program
• Note that the first due is
September 2nd for each of the
HVAC Assets (interval 9) of the
Cycle
• Additional due dates would be
shown next year for months 4
and 5, as well

Use Case 3
Setup
• Requirement: The HVAC system in a user’s facility typically requires that
the intake filters be changed every 1 month
– Additionally, every 3 months the Belts must also be adjusted and tightened. When a
Work Order is created, there does not need to be duplicate operation steps created
for the Technician.
– Create a Work Definition for the HVAC Filter change and an incremental Work
Definition for the Filter change and Belt adjustment
changed
34

Use Case 3
Work Requirement
35
• Set the override = Y and the
option to Suppress
• Add the Work Definition for
the Filter Change, making
sure it repeats every month
• Add the Work Definition for
the Filter Change and Belt
Adjustment, making sure it
repeats every 3 months
• Verify in the Forecasted To
column the intended
behavior
• Generate the Forecast

Use Case 3
Work Requirement
36
• When viewed in the
Forecast Gantt, we can
see that this Work
Requirement will
produce a single due
date every month,
however, the work scope
will include only the
operation steps required
for that interval

Use Case 4
Setup
• Requirement: The same company also requires maintenance on their
delivery truck. Here is their maintenance schedule:
– Every 5000 miles, the engine oil and filter require replacement
– Create a Work Definition for the Oil and Oil Filter change
– Create a maintainable Asset for each Delivery Truck that will need to have its oil and
oil filter changed
filter changes, using a Meter-based forecast
37

Use Case 4
Work Requirement
38
• Define a Non Cycle-based
forecast, as the Meter does
not require it for this case
• Use a start date of sysdate,
since we wish to consider
Meter reading history of
each Asset < Sysdate
• Optionally: Override the
suppress Merge header level
attributes if multiple
requirements are created for
the same Asset in this
Maintenance Program

Use Case 4
Work Requirement
39
• Truck 2 – had a meter reading of 32,500 on July 1st. The system will then assume that the oil
was changed at 30,000 miles and is due in 2,500 miles at 35,000 miles = 20th August
• Truck 1 – starting on July 1st, the system will calculate at a Daily Rate of 50 miles per day, it will
be due in 100 days from July 1st = 9th October
• Truck 2 – had a meter reading of 55,500 on July 17th, the day before the forecast starts. The
system will then assume that the oil was changed on this date at 55,000 miles and is due in
5000 miles at 60,000 miles = 25th October.

Use Case 5
Setup
• Requirement: The same company also requires different maintenance on
their delivery truck over time. And each Truck has a different Tempo:
– Delivery Truck 1 – 30 miles per day
• Every 7000 miles, the engine oil and filter require replacement
• Every 14000 miles, the engine air cleaner element requires replacement
40

Use Case 5
Setup
– Create a unique Work Definition for the Oil and Oil Filter change
– Create an “Add-on” Definition for the Engine Air Cleaner Element Change
– Create a maintainable Asset for each Delivery Truck that will need to have its oil and
oil filter changed. For each Asset’s Meter, update the Daily Rate accordingly:
• Truck 1 = 30 per day, Truck 2 = 50 per day and Truck 3 = 70 per day
– Create a new Maintenance Program, with an Asset-based Work Requirement for each
asset, using a Meter-based forecast
41

Use Case 5
Work Requirement
42
• Create individual Work
Requirements, one for each
Asset, that are Meter-based.
– Asset based
– Cycle with 2 intervals
– Override option and Merge
selected
– Select a Meter-based forecast

Use Case 5
Work Requirement
43
• Define the Meter:
– Select the Meter and set a Base
Interval (miles) per vehicle
– Set the calculate next due to Last
Completion
• Add Work Definitions
– Add Work Definition for the Oil
Change, set at interval 1 and
repeating
– Add Work Definition for the Air
Filter Change, set at interval 2
and repeating
– These will Merge at every
overlapping interval, which
supports the “Add-on” Work
Definition approach

Use Case 5
Work Requirement
44
• After running the forecast,
we can see that each Work
Requirement will produced
due dates based on when the
next maintenance interval of
5,6 and 7K occurs:
– The due dates are displayed for
Trucks 2 and 3 as they have
repeating Maintenance due this
year
– Note that Truck 1 won’t be due
until next year, as it has a Daily
Rate of 30 miles and 7000 miles
threshold, so 233 days from
today.
• Each due date will include an
oil or oil and air filter change

Use Case 6
Setup
• Requirement: The same company also requires maintenance on their
delivery truck to happen at different mileage intervals:
– 1st Maintenance will be done for 40,000 miles and then every 60,000 miles
• 1st – 40,000 miles
• 2nd – 100,000 miles
• 3rd – 160,000 miles and so on…
– Create a Work Definition for the service
filter changes, using a Meter-based forecast
– Define a common Base Interval and Cycle Interval based pattern
45

Use Case 6
Work Requirement
46
• Create a Meter-based
requirement:
– Asset based
– Cycle with 50 intervals (1M
Miles)
– Override option and Merge
selected
– Select a Meter-based
forecast
• Set Work Definitions to
be due at different
intervals:
– 2 = 40,000 miles
– 5 = 100,000 miles
– 8 – 160,000 miles

Oracle_SCM_Maintenance_TipsNTricks.pdf

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