Support Technical Exchange:
Preventive Maintenance and Condition Monitoring
Ed Jones
23 Aug 2012
Introduction
Abstract:
To provide an overview of the Preventive Maintenance and
Condition Monitoring applications in Maximo 7.5 and point
out the changes since Maximo 6
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Definitions
Preventive maintenance (PM) is a maintenance program with
activities initiated at predetermined intervals, and intended to
reduce the probability of failure, or the degradation of the
functioning of an item. (Linear and Nonlinear Preventive
Maintenance Models, Wu)
It is typically divided into
– Planned
– Condition-based
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Maximo Applications
Preventive Maintenance
– Org App
– Preventive Maintenance
• Forecasting
– Master PM
Condition Monitoring
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Preventive Maintenance (PM) Application – (Org App)
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PM Application
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PM Application – (Frequency Tab)
Is the interval Is the interval determined by Is the interval determined by
determined by a time? meter(s)? both?
Enter the time-based Enter the meter(s) Enter the meter(s)
freq
AND
Enter the time-based
freq
Note: All meters require an average calculation, even if you plan to use exact meter readings to drive PMs.
The average is used for forecasting purposes.
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PM Application – (Frequency Tab)
Check this option to keep a fixed schedule. Uncheck it to
have a ‘floating’ schedule (for example if the PM work will
keep the asset will be in the shop for a number of days)
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PM Application – (Frequency Tab)
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PM Application – (Frequency Tab)
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A bit about meters...
There are three types of meters in Maximo
– Continuous (aka counters)
• Numeric
• Odometer, etc
– Gauge (aka fluctuating)
• Numeric
• Thermometer, etc
– Characteristic (aka observation)
• Domain (list of values)
• Oil color, etc
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A bit about meters...
They are all ‘abstract’ meters, typically a (non-
asset) component of an asset (e.g. a car odometer)
or non-existent (e.g. tracking run hours manually)
If you have a physical meter that you are managing,
create it as an asset
– This is the approach for utility meters
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A bit about meters…
Meter Application
Meter
Continuous Gauge Characteristic groups
Asset (or Asset Template) /Locations Item
Meter readings Measurements
PM Condition Monitoring
Work Orders
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PM Application – (Frequency Tab)
Meter average calculation methods (Asset App)
Does the usage
All
fluctuate irregularly
Is the usage per day
Static
fixed
Does usage
increase/decrease Sliding days
every n days
Does the usage
increase/decrease Sliding readings
every n readings
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PM Application – (Frequency Tab)
Meter-based PMs allow users to generate work orders with
greater accuracy by leveraging usage in lieu of time-based
estimates.
Accuracy is only achieved, however, if the meter readings in
Maximo kept in sync with the meter readings of the asset.
This means entering readings into Maximo as soon as
possible after they are obtained.
To further increase accuracy, the ‘Do Not Estimate’ option should be
used. Average
To further meter
increase readings
accuracy, were
the ‘Do Notused for work
Estimate’ optionorder generation
should be
prior
used.toAverage
the existence of meter
meter readings reading
were history,
used for and are
work order now only
generation
recommended for forecasting
prior to the existence resources.
of meter reading history, and are now only
recommended for forecasting resources.
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PM Application – (Seasonal Dates Tab)
Want PMs only to be generated M-F? Then use active days
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PM Application – (Seasonal Dates Tab)
Want to ensure work orders for inactive days are pulled in, and
not pushed out?
Check Schedule Early on Frequency Conflict?
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PM Application – (Seasonal Dates Tab)
Want to set a start time on the work orders?
Set the Target Start Time:
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PM Application – (Seasonal Dates Tab)
Did you know that by creating a PM with a frequency of 1 day,
an ‘Active Date’ window for each month, from 1-7, and setting
the ‘Active Days’ to Monday, you’ll get a PM on the first
Monday of each month?
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PM Application – (Job Plan Sequence Tab)
Used to rotate through a series of job plans (e.g. Monthly, Quarterly, Annual)
The Job Plan is selected by dividing the PM Counter by the Sequence
#. The largest, divisible sequence # will be selected.
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PM Application – (PM Hierarchy Tab)
Used to as a means of creating a hierarchy of work orders
You can determine which PMs in the hierarchy trigger the hierarchy
when they become due via the Use this PM to Trigger PM Hierarchy?
Checkbox on the main tab
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PM Application – (PM Forecast Tab)
Used to project resource requirements without generating actual work orders
Meter-based forecasts will use the average meter units per day
calculation – even when the PM itself will use the exact meter
reading…Remember – this is a forecast…
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PM Application - Forecast
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PM Application - Forecast
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PM Application – (PM Forecast Tab)
Time-based PMs
– First Forecast Date = Estimated Next Due Date
• where Estimated Next Due Date = Current Date + Frequency
(Frequency/Units)
– Subsequent Forecast Dates = Previous Forecast Date + Frequency
Meter-based PMs
– Estimated Next Due Date = Last Start Date + (Meter Frequency
days/Average Meter Units per Day)
– Subsequent Forecast Dates = Previous Forecast Date + (Meter
Frequency days/Average Meter Units per Day)
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PM Application – (PM Forecast Tab)
Created to work in conjunction with Maximo Asset
Management SchedulerSingle forecast for a PM
– Utilizing the same PM criteria already used in the PM application
– Definable forecast range
– Respects Seasonality, Hierarchy, Job Plan Sequence just as the
current PM application does
– Editable forecast dates
– Cron task to leverage an automated means to maintain the “forecast
window”
– Stays in lock step synchronization with the generation of PM WO
from the PM application
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The “Sliding” Forecast Window
The forecast window “slides” consistently with time, as current PM
dates are consumed and new ones added … the forecast window is
automatically maintained
New distant forecast dates
appended to the forecast
Forecast
Window
(Constant)
PM Forecast Dates
Time
Current Date
Current forecast dates for
new PM Work Orders
that are now due
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The “Sliding” Forecast Window
The forecast window “slides” consistently with time, as current PM
dates are consumed and new ones added … the forecast window is
automatically maintained
New distant forecast dates
appended to the forecast
Forecast
Window
(Constant)
PM Forecast Dates
Time
Current Date
Current forecast dates for
new PM Work Orders
that are now due
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Master PM Application
Used to create associate PMs for assets having
the same item number as that on the Master PM
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A reminder about meters …
Meter Application
Meter
Continuous Gauge Characteristic groups
Asset (or Asset Template) /Locations Item
Meter readings Measurements
PM Condition Monitoring
Work Orders
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Condition Monitoring Application
Using threshold values from gauge or
characteristic meters to trigger generation of work
orders
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Condition Monitoring Application
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Condition Monitoring Application
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Reference Materials
Passport Advantage
– Maximo 7.5 download
Info Center
– Preventive Maintenance Module
– PM Forecasting
RedBooks
– Maximo User Gudie
Service Management Connect
– Asset Management
– Maximo 7.5 Upgrade
– Request For Enhancement (RFE) Community
DevelopWorks
– Maximo forum
Support
– Support home
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Wrap-Up
To provide an overview of the Preventive Maintenance and
Condition Monitoring applications in Maximo 7.5 and point
out the changes since Maximo 6
– Preventive Maintenance provides the ability to set up recurring work
based on time or meter based frequencies.
• PM Forecasting is new in 7.5
– Condition Monitoring allows you to trigger work orders based on a
gauge or characteristic meter threshold.
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B
M
Questions?
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