Maintenance Management System User Manuals
Contents
Overview
This ADempiere business process supports both Preventive and Corrective Maintenance. It was developed with integration of current ADempiere objects in mind. Equipment maintenance is required for mobile equipment (e.g. buses, trucks, etc.) and fixed plant equipment (e.g. conveyor belts, crushers, etc.). Mobile equipment maintenance is a much more complex business process than fixed plant maintenance due to the rather randomly operational environment where maintenance occurs, fixed plant maintenance requirements is mostly considered a subset of mobile equipment maintenance requirements. This development was designed to cover mobile equipment maintenance and, hence, supports most fixed plant maintenance requirements.
Assets Groups
Meters
Meters are used to measure equipment life. This life and the average of daily usage are used for the set up of the different maintenance plans. Meters are entered in the Meters window. Given that a meter can be changed at some point of the equipment life, the meter is automatically prefixed with the asset(equipment) number where the meter is installed and the identification is completed with a serial number entered by the user.
When completing the creation of a meter, the user has to select a meter type (kilometers, tons, hours) and the maximum allowable reading per day, this value helps filtering out data entry errors in equipment usage.
Meter Log
There are 2 windows where daily readings can be entered for an asset.
The first method is via the ADempiere asset window, the reading can be entered by selecting the "Meter Log" tab and then entering the meter type, the day of the reading and the reading value. The reading value is the accumulated life value as shown by the physical meter. If the value is lower than a previous reading or the value is higher than the daily usage entered when creating the meter, a warning prompt will be displayed.
The second method for entering a reading is using a new "Meter Log" window as shown below. This window is the preferred method when entering a set of daily readings for all the equipments in the company so you can skip a step of selecting an asset in order to enter the reading.
Standard Jobs
Maintenance planning is the action of defining all the maintenance tasks required by a piece of equipment, how often these tasks are required and what resources are needed in order to complete the tasks.
A standard job(SJ) is the entity where all the maintenance planning is completed.
The Standard Job window in ADempiere has 3 tabs, namely, header, tasks and resources. As in all the other standard forms in ADempiere, this means that a single SJ can have unlimited multiple tasks and each task can have unlimited multiple resources.
In the header tab, the user can entered if the SJ is defined for a single equipment or for a group of equipments (Asset Group). Definition of a maintenance area can also be entered. A read only field with summary costs of this SJ is displayed. Calculation of these costs depends on the information entered in the resources tab.
The maintenance tasks are the steps that are required to be completed for the SJ to be executed. User needs to describe the task and the related duration in this tab.
In the resources tab, user can select the type of resource (spare part, BOM, maintainer, etc.), resource (type of maintainer to complete the task), a specific BOM to be used, a product (a single spare part), the quantity of the resource required and the estimated cost of the resource. Some of the above fields are dynamically displayed depending on the type of resource selected.
Preventive Maintenance(PM)
This window is used to create the different plans for Preventive Maintenance for your company equipments.
A PM can be completed either by filling up the different field in the task and resources tabs or by nominating a Standard Job (SJ) to be used as a template for this PM creation. In the later case, all the information from the nominated SJ will be automatically filled in the corresponding fields.
Each PM has a unique identifier (document number), and as seen in the header window can be created for a single equipment or a group of equipments.
The field "ischild" must be ticked if the PM is part of a nested maintenance plan. Nested maintenance are a set set of PM that are related by the interval of equipment (each member of a nested family of PM occurs in a integer number of times a the interval of a lower interval famili member PM). A close example of a nested PM is when a PM for a car is perfomed each 10.000 kms but the 20.000 kms event is equal to a 10.000 plus some aditional tasks, performing the 20.000 resets the interval of both the 10.000 and the 20.000 events (because in essence you performed both at 20.000 kms)
In the header tab of the PM window, all the information required for scheduling this PM events are set up in the "Scheduling subsection", in that section the following important fields have to be filled:
- Scheduling Type, typically meter or calendar
- PM Meter, Meter to be used to measure the interval between maintenance events
- Interval, interval between two PM of the same type
- Range, This is an offset value in the interval, if the forecast calculates that on a certain date the equipment will have met the interval within (+/-) this range, it will schedule the PM
The tasks and Resources tabs of the PM window are a mimic of the SJ Tasks and Resources tabs.
PM Prognosis(forecast)
The PM prognosis is an ADempiere process that forecasts all PM events for a certain number of periods (weeks) in the future. In order to forecast these PM events, the process takes into account the following:
- equipment life when last PM of the same time was performed
- Interval of each PM for all equipments
- Range
- Average daily usage
