Wednesday, October 31, 2012

Using Job Plans and Preventive Maintenance in Maximo 7.5

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Using Job Plans and Preventive Maintenance in Maximo 7.5 guide will introduce you on creating job plans and preventive maintenance records for periodic maintenance and inspections to be performed on an asset. This guide will also discuss on how to associate Job Plans to Preventive Maintenance. This enables users to automatically generate work orders for the maintenance of all assets and locations in a scheduled time.

Maximo Job Plans will help end users to create an organized approach for future work activities. These serve as templates for future work activities that are done regularly or repetitively.
Job Plans when created have an initial status of DRAFT. This status needs to be changed to ACTIVE status before it can be used on a Work Order or associated with Preventive Maintenance Record. A job plan record may be used countless times by inputting the Job Plan number in the Job Plan field of Work Order Tracking, or by associating it with a Preventive Maintenance record. The Preventive Maintenance record will be used to generate periodic Work Orders. Using Job Plan records will help users save time, since users don’t need to manually enter the operating steps, planned labor, and material resources each time a PM work order was generated.
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Job Plan Screen:
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1.Sign in to Maximo
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2.Go to > Planning> Job Plans to open the Job Plan application.
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3.Click the New Job Plan button.
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4.Enter a value for the Job Plan record number and all other required fields. Required fields contains asterisk (*) before the field label.
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5.Save the record by clicking the Job 6 icon on the toolbar.
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Primary Job Plan Fields
Job Plan
This is the unique identifier for Job Plan to easily identify the record.
Description
Provides a short description for a Job Plan. A long description field beside this field that can be used when a record needs a longer and more specific instruction details.
Organization/Site:
If these fields are left blank, this means that the Job Plan can be used to all Organizations or Sites. Use these fields to limit the Job Plan record to a specific Organization or Site.
Status
Newly created Job Plans begin with a status of DRAFT. Job Plan records which have DRAFT status cannot be associated with any records. Job Plans should be changed to ACTIVE status before you associate it with Work Orders or PM records. Another status which will block the functionality within other application is INACTIVE status.
Template Type
This field allows users to create a division for Job Plan types. Types include Activity, Maintenance, and Process.
WO Priority
Priority of Work Orders to be generated.
Supervisor
This will indicate the Supervisor which will take the responsibility of the generated Work Order.
Duration
Duration of time to complete the task.
Lead
Defines the Lead person who will be copied to the work order created with this job plan
Work Group
Designated Person Group for the Work Order.
Owner/Owner Group
The person or person group who will be responsible for the created Work Order.
Interruptible
Identifies if the task must be completed in a single setting, or it can be started and stopped.

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1.Click the New Row button in the Job Plan Tasks section.
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2.Enter a number in Task ID field, or accept the default number.
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3.Optional: Enter a description of task in the Description Field.
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4.Enter a sequence number and estimated time for completion, if needed.
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5.Repeat steps 1-4 until all tasks have been added to the Job Plan record.
6.Save the record.
Job Task Fields:

Task ID:
This is the unique identifier of tasks under a Job Plan record. A required field which is non-editable when the record is saved.
Description
Describes the Task to be completed for the Job Plan. Long description can also be included using the long description button beside the field if the task needs a more detailed description.
Duration
Time needed to complete the Task.

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Job plan estimates can be added to record all planned Labor, Materials, Services, and To
1.Click the New Row button on the sub-page tab where you want to create an estimate.
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2.If the selected labor needs to perform a specific task on the job plan. Leave it blank if not needed. The image below indicates that the labor Mike Wilson will perform the Task 10 of the job plan record.
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3.Another option is that you can modify the set estimated hours for Labor or uantity for Materials, Services and Tools.
4.Repeat steps 1-3 until all estimates have been added to the Job Plan.
5.Click Save button to complete.
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You can register Locations and Assets on a Job Plan using the work Assets tab.
1.Click the New Row button under Work Assets tab.
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2.Select Location or Asset using the lookups.
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3.Click Save when done.
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Instead of listing individual task in a job plan, you can use the nested job plans option which will enable you to add a job plan record that contains tasks needed for the associated job plan. This is a useful feature in a job plan as it will save time for the users to load Job Plans for assets with different build types. For example, your Organization has a default sets for cleaning air conditioners. However, cleaning of other brands may require additional unique steps to properly check the unit.
In the example below, Task 30 is to check Freon level. A job plan for HVAC System Inspection is nested into Task 30.
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When the created job plan that contains nested job plan record is included to a Work Order, the main tasks will be included on the primary Work Order. A Child Work Order record will be created which contains the steps for HVAC System Inspection.
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Preventive Maintenance (PM) records are used to generate preventive maintenance work orders. Job plans can be incorporated in a preventive maintenance record. This is commonly used on assets and locations that require periodic maintenance to maximize the performance and avoid untimely failures. This is necessary for Organization to extend useful life of their assets and locations.
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Preventive Maintenance Fields:

PM Number
This is the unique identifier of a Preventive Maintenance record. Every PM record is specific only to one Asset or Location record.
Description
Describes the Preventive Maintenance record
Location/Asset
Asset or Location where the preventive maintenance will be done.
Route
A route is a list of stops that represent asset or work locations. If a work order is generated from a PM that has associated route, a parent work order will be created for the associated asset or location and a child work order for each asset in the route list.
Lead Time (Days)
This indicates the number of days to be considered before the actual work can be started. For example, it will take 2 days to deliver the spare parts needed. You just need to input the number of days in this field and this will be added to the number of days entered in the Generate Work Order dialog box. When using Lead Time option, ensure that the Lead Time Active check box is checked.
Counter
This indicates the number of generated work orders from the PM since the first generation of the record. This resets when a new PM record is inserted.


Welcome to the final part of series about Using Job Plans and Preventive Maintenance in Maximo 7.5

Use Job Plan Sequences
When checked, this indicates that the PM uses job plan sequences which will generate different work orders each time based on a job plan sequence. If it is left unchecked, PM will generate the same work orders every time.
Work Order Status
Indicates the status of the PM. Newly created PM records will have a DRAFT status and Active status for active PM’s and INACTIVE for non active PM’s.
Supervisor
Contains the supervisor name that will be responsible for assigning resources such as Labor to Work Orders generated from the PM.
Storeroom
If a Job Plan has estimated materials, Maximo needs to know the Storeroom to create the item reserved.
Lead/Work Group/ Owner/Owner Group
This will contain on which person or group is responsible for the work activities of generated Work Orders.
WO Priority
Priority to be set for the work order to be generated.
Interruptible
If checked, the work order is allowed to be stopped and restarted. If unchecked, the work order should not be interrupted.
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Scheduling of PM Work on most assets can be done on a date driven basis, daily, weekly, monthly, quarterly or annually. For other assets, usage function can be used to schedule a preventive maintenance work. Maximo 7 also supports dual triggers. For example, a car requires an oil change every 3 months or 5000 kilometers, whichever comes first. Maximo will generate a work order record for a preventive maintenance work once the car reached the 5000 kilometers or 3 months whichever comes first.
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This controls the timing of Work Order generation under the selected PM record. There are 2 types of frequency that can be used:
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1.Time Based Frequency – This can be used when you need to schedule the generation of Work Order generation by calendar unit. Choices include days, months, weeks, years.
2.Meter Based Frequency – Generation of Work Order will be based on meter readings.
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PM Work Orders can be generated automatically or manually. In able to generate it automatically, there is a Cron Task available which is called PMWoGenCronTask. Maximo user with administrative privilege can schedule the generation of PM Work Order using the Cron Task Setup. Once the Cron Task is activated, Maximo will begin to execute the process depending on the schedule setup.
Manual PM Work Order generation lets the assigned person to generate their own PM Work Orders on the time they want. Always consider that only active PM can generate work orders.
1.Go to PM Application
2.Select the PM you want to generate a PM Work Order
3.Go to Select Action Menu.
4.Fill in the necessary details.
Generate WOs Due Today Plus This Number of Days
Gives additional days before the PM Work Order should be generated.
User Frequency Criteria
This field is checked by default. This will look at the next due date of the PM record to determine if it needs to generate a Work Order. If this field is left unchecked, this will disregard the frequency settings and will generate a Work Order whether the due date has been reached or not.
Run Work Order Generation in Background
If this field is checked, users can continue working on their Maximo screen without interrupting the generation of work orders. If left unchecked, the generation activity window will be shown.
Notification E-mail
The e-mail address listed in this field will receive a copy of the PM log file when the PM Work Order generation has completed. This includes the PM and Work Order numbers generated.5.System message will be displayed containing the details for the generated PM Work Order.

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5.System message will be displayed containing the details for the generated PM Work Order.

13 comments:

  1. Hi, I just want to know how I can make 2 PM working together (father-children). My scenario : 1 PM for each day and 1 PM for each week. When I generate the days, the 2 PM are create each days. If you can help ?
    Thanks



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  2. Yes, create two job plans. One plan will be daily, the other your weekly. Put the two plans on your PM and make the daily sequence 1 and the weekly sequence 7. The workorders will generate with the daily task each day and on every 7th day the weekly jobplan task will be on the workorder instead of the daily. You will have a single PM with alterating tasks every 7 days.

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  3. Hi, I am creating PM using MIF , having values ASSETNUM, MASTERPM, LASTCOMPDATE, DESCRIPTION, SITEID, ORGID . PM is created using this value but Status is DRAFT and not pull values from masterPM. what to do for change status - Active. and how I will get MASTERPM values in PM?

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  4. Dear Mr Manoj, a cannot open the pictures of this page, can you help me? this guideline will be fantastic for me iif i were able to display correctly. Thank you very much in advance, Lorenzo

    ReplyDelete
  5. Hello,
    I'm wondering if it is possible to create a hyperlink to a pre-existing PM so that I can click a link on a PDF and have it open up the PM in Maximo.
    Regards,
    Andrew.

    ReplyDelete
  6. Manoj,
    I'm acustom to using SAPgui, but this company I am with now chose Maximo 7.5.1. I need to create a daily maintenance schedule. Maximo seems to be designed around a utility, we are a manufactoring company. it's only used here for maintenance assignments for the men. I am having to export to BIRT, from BIRT to a report in PDF BIRT, then copy/paste to an Excel schedule format. I also weekly, must creat a metrics report from Maximo for the schedule to show scheduling compliance. Such as break in work, and add-on work to the schedule. Maximo only has a KPI to do PMs. I can't create a KPI for the other metrics because Maximo don't have a scheduler to pull data from. I need a some good suggestions on how this all can be done within Maximo. I had hopes with 7.5.1 & 7.5.2, but it's mostly a Gantt chart. No maintenance crew can use a Gantt chart to assign daily work. Gantts are used to show conflict to prevent jobs being scheduled on top of each other and estimated time line. SAP offers a Gantt but it will pull data from the daily schedule to create a Gantt if you need it. You can toggle back and forth from Gantt to schedule IF you need to. But we would only need to do that once a year, just to make the powers that be happy. Last Gantt chart, they never even looked at it. Total waist of time to create. Help please!

    ReplyDelete
    Replies
    1. I have the same situation master data user in SAP now i'm in the stone ages trying to use maximo that does not seem made to accommodate a good preventative and future maintenance plan. This is a horrible way to build workable plans.

      Delete
  7. Hello,

    I am setting up PM's to be scheduled daily however currently I have to go in everyday and create a work order, then assign an owner and approve it. I have never heard of this, "PMWoGenCronTask" however from reading above it looks like this is what I need to do to get the PM to generate a work order everyday. Am I missing something? I just want it to generate a work order for a PM everyday? How do I do this?

    ReplyDelete
  8. Go To>System Configuration>Platform Configuration>Cron Task Setup
    Open PMWoGenCronTask and click New Row to create a new instance and specify the details.
    Ours is scheduled to run once a week, Tuesday, 2 a.m. Two plants generates work order for a week while the third plant for 3 weeks. This is set up in GO To>Organization>PM Options. Set the value in “Generate WOs Due on the Current Date Plus” filed.
    You could set your PM frequency for daily and PMWoGenCronTask for once a week. Although the corn task runs weeks, it will generate all the work orders that are due in the period set up by the PM Option. This works better for our planning than daily printing of PMs.

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  9. Can we set up a schedule in pm program for doing regulatory inspections and permitting. If so how would we set up. Would it be in work type.

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  10. Mo PMWoGen Cron Task won't generate what I want using this where clause in the PM options i.e next months tasks. It seems to ignore the where clause.
    WORKTYPE='PLND' and status='ACTIVE' and nextdate > last_day(sysdate) and nextdate < last_day(add_months(sysdate,1))

    ReplyDelete
  11. Hi and first thanks for your blog.

    We have large works for a Power Generation which is to be done every 48M on the gas generator. But also on many equipment around (instrument, electrical, valves...) which are to be done every 12M.

    The location hierarchy is the following one:
    POWER_GENERATION_1
    |- GAS_GENERATOR_1
    |- INSTRUMENT1
    |- VALVE1

    Each location should have their own work order.

    We would like to have the following WO built by a PM
    WO00001 - YEARLY POWER_GENERATION_1 MAINTENANCE
    ¦- WOOOO2 - INSTRUMENT1
    ¦- WOOOO3 - VALVE1
    ¦- WOOOO4 - ...

    and every 48M
    WO00100 - 4Y POWER GENERATION MAINTENANCE
    ¦- WOO1O1 - GAS_GENERATOR_1 MAJOR MAINTENANCE
    ¦- WOO1O2 - INSTRUMENT1
    ¦- WOO1O3 - VALVE1
    ¦- WOO1O4 - ...

    thanks,

    ReplyDelete
  12. Is there any ways to set up PMs to generate on the 3rd week of every month?

    ReplyDelete