Using Enterprise Asset Management Preventive .pdf

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
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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

Overview
Why preventive maintenance
Prevent expenditures in terms of work time losses, downtime impacts,
opportunities lost etc
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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.

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
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Generate work
orders
Complete WO
and PM cycle

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
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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

Meters
Meters need to be defined separately and associated with an asset or asset
group
Meters – Absolute and Change types
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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

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
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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

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
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• 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

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
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

Last Service Information
14

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
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

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
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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

Activities, Cycles and Intervals
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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?
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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

Example
Base Interval – 15000 miles
Oil Change – 15000 miles, Repeat in Cycle = N
Tune Up – 30000 miles , Repeat in Cycle = N
No Manual Work Orders.
What work orders are
generated?
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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

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
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– 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

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.
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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’

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
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(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……..

Base Date option
Base
Date
WO-1(Comp)
Rule – Suggest a work order every 25 days
WO-2
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25
0
Date
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Last Service Date

PM Work Orders generation – two options
Maintenance Workbench
A flexible option that allows viewing asset work orders and also has
simulation capabilities
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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

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
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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.

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
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CSI_COUNTER_ASSOCIATIONS Contains the Asset Meter Association
CSI_COUNTERS_B Meters/Meter Template table
Generate Preventive Maintenance
Work Orders
The executable is EAMPMSDU

Best practices
Focus preventive maintenance effort on critical assets
High Number of Repair and emergency Work Orders
High Maintenance Cost
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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)

Summary
Need for Preventive Maintenance
Setting up and planning for PM
Using EAM PM and best practices
What we covered
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Using EAM PM and best practices

QUESTIONS

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ANSWERS

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