Testing Maintenance Management functionality based on Libero Manufacturing

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Preventive Maintenance for the car

Proposal

Create a complete example Testing Maintenance Management functionality (Preventive maintenance for the car) based on Libero Manufacturing in ADempiere's GardenWorld sample test client.

Introduction

Preventive maintenance is a necessary expense to keep your vehicle in good running condition. Following the scheduled maintenance recommendations in your owner's manual, checking fluid levels regularly and changing the fluids and filters periodically can minimize the risks of breakdowns and prolong the life of the engine, transmission, cooling system and brakes. So if you are driving a "maintenance challenged" vehicle, you need to pay closer attention to your fluids and filters.

Project Lead

Coordinator

Testers

Requirements

The Maintenance Management will be based on the 3 types of Preventive Maintenance for the Car which are: (1) Preventive Maintenance 1, (2) Preventive Maintenance 2 and (3) Preventive Maintenance 3.

The objectives here are to:

  1. Test such seed or sample data for ADempiere standard Maintenance Management
  2. Form part of the ongoing Libero Manual or any related documentation.
  3. To promote to the whole world about the new Maintenance Management functionality of ADempiere.
  4. To advance ADempiere as the best open source ERP solution for the Maintenance Management and Manufacturing industry.

Design Maintenance Environment

New Organization

  • Created new Maintenance Organization Type

Maintenance Org Type.JPG

  • Created new Maintenance Organization

Maintenance Org.JPG

New Warehouses

There are various locators defined which are:

  • Created new Warehouse: Maintenance

Maintenance Warehouse.JPG

  • Created new Warehouse: Spare Parts

Maintenance Warehouse SP.JPG

New Assets Group

  • Created new Assets Group: Transport

Maintenance Asset Group.JPG

New Product Category

  • Creted new Category: Transport for Fixed Assets

You should select the value = Transport to the Assets Group. Maintenance Product Category Transport for FA.JPG

  • Created new Category: Spare Parts

Maintenance Product Category.JPG

New Business Partner

  • Created new Business Partner: Mercedes company

Maintenance BP Mercedes.JPG

  • Created new Vendor Tab for the Mercedes company

Maintenance BP Mercedes VendorTab.JPG


???-Maybe later we should add new Business Partner for Subcontracting.

New Product

  • Cars
    • Mercedes-Benz 220

Maintenance Product MB220 for FA.JPG

  • Spare parts
    • We should add to the Spare parts:
      • Motor oil
      • Motor oil filter
      • Air filter
      • Antifreeze
      • Automatic transmission oil
      • Automatic transmission filter Belt
      • Spark plugs
      • Fuel filter
      • Brake fluid
      • Cabin air filter
  • For this you go to the menu for addition of new Spare parts:

Maintenance Menu SP.JPG

  • MOTOR OIL

Maintenance SP MOTOR OIL.JPG

  • OIL FILTER

Maintenance SP OIL FILTER .JPG

  • AIR FILTER

Maintenance SP AIR FILTER.JPG

  • ANTIFREEZE

Maintenance SP ANTIFREEZE.JPG

Define Planning Data for Spare parts necessary to MRP

  • You can add info to Replenish Tab for Spare parts

Maintenance SP ReplenishTab.JPG

  • You can add info to Purchasing Tab for Spare parts

Maintenance SP PurchasingTab.JPG

New Asset

  • Mercedes-Benz 220

Maintenance Asset MB220.JPG

Maintenance Management Setup

Resource

  • PLANT MAINTENANCE
  • AUTO MECHANIC - HR
  • DIAGNOSTIC OUTSIDE PROCESSING

Define Rate Labor and Burden Rate for Resource

Tools

  • PROFESSIONAL TOOL KIT - PRODUCT or ASEETS
  • CAR WORKSHOP EQUIPMENT - ASSET

Bill of Material

Simple Preventive Maintenance card for the Mercedes-Benz cars (for this test)

I think we should create three BOMs for Preventive Maintenance:

  • Preventive Maintenance 1 - through each 15 000 km
    • BOM Products
Component Component Type Quantity
Motor oil Component 5.8 litre
Motor oil filter Component 1 Each
Air filter Component 1 Each
Professional Tool Kit Tools 1 Kit
Car Workshop Equipment Tools 1 Kit


  • WORKFLOW
    • We should do the next activities:
Search Key Activity Resource Setup Time Duration Time
10 Replacement the Motor oil AUTO MECHANIC,CAR WORKSHOP EQUIPMENT,Professional Tool Kit
_11 AUTO MECHANIC should lift up the car on the CAR WORKSHOP EQUIPMENT AUTO MECHANIC,CAR WORKSHOP EQUIPMENT 5 min 5 min
_12 AUTO MECHANIC should remove a stopper and merge old oil AUTO MECHANIC,CAR WORKSHOP EQUIPMENT,Professional Tool Kit 2 min 30 min
_13 AUTO MECHANIC should fill a liquid for motor washing AUTO MECHANIC,CAR WORKSHOP EQUIPMENT,Professional Tool Kit 2 min 5 min
_14 AUTO MECHANIC should start the automobile motor AUTO MECHANIC,CAR WORKSHOP EQUIPMENT 1 min 10 min
_15 AUTO MECHANIC should remove a stopper and merge the liquid for motor washing AUTO MECHANIC,CAR WORKSHOP EQUIPMENT,Professional Tool Kit 2 min 20 min
_16 AUTO MECHANIC should fill a new motor oil AUTO MECHANIC,CAR WORKSHOP EQUIPMENT,Professional Tool Kit 2 min 5 min
_17 AUTO MECHANIC should lift down the car on the CAR WORKSHOP EQUIPMENT AUTO MECHANIC,CAR WORKSHOP EQUIPMENT 1 min 5 min
20 Replacement the Motor oil filter AUTO MECHANIC
30 Diagnostics the Air filter AUTO MECHANIC
40 Diagnostics the Cooling system:antifreeze AUTO MECHANIC
50 Diagnostics the Automatic transmission oil AUTO MECHANIC
60 Diagnostics the Automatic transmission filter AUTO MECHANIC
70 Diagnostics the Belt AUTO MECHANIC
80 Diagnostics the Brake fluid AUTO MECHANIC
90 Diagnostics the Cabin air filter AUTO MECHANIC


  • Preventive Maintenance 2 - through each 30 000 km
    • BOM Products
Component Component Type Quantity
Motor oil Component 5.8 litre
Motor oil filter Component 1 Each
Air filter Component 1 Each
Spark plugs Component 4 Each
Cabin air filter Component 1 Each
Fuel filter Component 1 Each
Professional Tool Kit Tools 1 Kit
Car Workshop Equipment Tools 1 Kit
  • WORKFLOW
    • We should do the next activities:
Search Key Activity Resource Setup Time Duration Time
10 Replacement the Motor oil AUTO MECHANIC
20 Replacement the Motor oil filter AUTO MECHANIC
30 Replacement the Air filter AUTO MECHANIC
40 Diagnostics the Cooling system:antifreeze AUTO MECHANIC
50 Diagnostics the Automatic transmission oil AUTO MECHANIC
60 Diagnostics the Automatic transmission filter AUTO MECHANIC
70 Diagnostics the Belt AUTO MECHANIC
80 Replacement the Spark plugs AUTO MECHANIC
90 Replacement the Cabin air filter AUTO MECHANIC
100 Diagnostics the Brake fluid AUTO MECHANIC
110 Replacement the Fuel filter AUTO MECHANIC


  • Preventive Maintenance 3 - through each 60 000 km
    • BOM Products
Component Component Type Quantity
Motor oil Component 5.8 litre
Motor oil filter Component 1 Each
Air filter Component 1 Each
Automatic transmission oil Component 5.5 litre
Automatic transmission filter Component 1 Each
Spark plugs Component 4 Each
Brake fluid Component 0.7 Litre
Cabin air filter Component 1 Each
Professional Tool Kit Tools 1 Kit
Car Workshop Equipment Tools 1 Kit


  • WORKFLOW
    • We should do the next activities:
Search Key Activity Resource Setup Time Duration Time
10 Replacement the Motor oil AUTO MECHANIC
20 Replacement the Motor oil filter AUTO MECHANIC
30 Replacement the Air filter AUTO MECHANIC
40 Diagnostics the Cooling system:antifreeze AUTO MECHANIC
50 Replacement the Automatic transmission oil AUTO MECHANIC
60 Replacement the Automatic transmission filter AUTO MECHANIC
70 Diagnostics the Belt AUTO MECHANIC
80 Replacement the Spark plugs AUTO MECHANIC
90 Replacement the Brake fluid AUTO MECHANIC
100 Replacement the Cabin air filter AUTO MECHANIC
110 Adjustment the Light (headlights) DIAGNOSTIC OUTSIDE PROCESSING

Setup Time: The required time to execute the actions of preparation of the resource specified in the node to be able to start the manufacturing process. To make the manufacturing schedule using the technique both forward and backward, the setup time is considered only once for every node in the manufacturing order.

Duration Time: The planned standard time to produce one unit of product in a node.


P.S. You look, pls, my comments and questions about this topic.

Maintenance Order

Maintenance Planning

Forecast

MRP

CRP

Test Scenarios

See Also

Talk:Testing Maintenance Management functionality based on Libero Manufacturing.