Defining a Preventive Maintenance Template

An Activity and Maintained Number combination can be associated with Runtime, Day Interval Rules, or a list of dates, defining when an Activity should be scheduled for an Asset, Serialized and Non-Serialized Rebuildables, or an Asset Route. Only Day Interval rules and List of Dates rules are supported for Non-Serialized Rebuildables and Asset Routes. The Preventive Maintenance (PM) Scheduler process creates suggested Work Order dates based on these rules. A planner can then view these forecasted Work Orders, and generate them as necessary.

There are two ways to create PM schedule definitions for Serialized Rebuildables and Assets. You can create them individually within the Preventive Maintenance Schedules window, or streamline the process of creating them using a PM Template. A PM Template is a schedule, defined for a Maintained Group (Asset Group or Rebuildable Item)/Activity association. If you utilize the PM Template functionality, a new PM Schedule is automatically created for a newly created Maintained Number (asset or rebuildable) for the Maintained Group. All PM Template attributes are copied over to the PM Schedule for the Instance. You can optionally modify the values of the PM Instances created.

Before a PM Template can be created, the following prerequisites need to already exist:
– Activity Definition
– Activity Association Template
– Meter Template Definition : A Meter Template definition is required only if the PM Template is based on Runtime Rules.
– Meter Template Association : A Meter Template Association is required only if the PM Template is based on Runtime Rules.

To create a PM Template:

Navigate to the Find Preventive Maintenance Schedules window. This window enables you to enter information to narrow your search for query mode. To define a new PM Template, choose New.
1.1. Enter a PM Template name in the Schedule Name field.
1.2 Select an Item Type from the list of values. Valid values are Asset and Rebuildable. If you select Asset, the Maintained Group fields refer to the Asset Group. If you select Rebuildable, the Maintained Group fields refer to the Rebuildable Item.
1.3 Enter a Set Name. A PM schedule for an Activity and Maintained Group must uniquely belong to a Set Name. Every Set Name has an end date. Every PM schedule that belongs to the Set Name must have its effective-to date before the end date of the PM Set Name. Before assigning a Set Name to a PM schedule, you need to define Set Names within the Set Name Definition window. If you do not want to create Set Names, you
can assign PM schedules to set, MAIN; it already exists.
1.4 Select a Maintained Group from the list of values.
1.5 Select an Activity from the list of values. Only Activities associated with Maintained Groups are eligible for defining a Schedule Template.
1.6. Select a Schedule Type from the list of values. Valid values are Rule Based and List Dates. If you select Rule Based, the Day Interval Rules and Runtime Rules tabbed regions are enabled to enter information. If you select List Dates, you
will define information within the List Dates tabbed region.

1.7. Optionally, select the Instantiation check box. If this check box is selected, a new instance of the current PM schedule template is created for each new Maintained Number (Asset Number or Rebuildable Serial Number).

2.1 The Effective dates will default from the current Activity, if they exist. Optionally, select or update the Effective From and Effective To dates.
2.2. Optionally, enter a Lead Time In Days.
Lead time in a Preventive Maintenance Schedule is different than lead time associated with Work Order creation. The Preventive Maintenance process suggests Work Orders to be created or scheduled, starting from the last service day of the Asset to the cut-off day you specified while running the process. If a Lead Time In Days is specified, the Preventive Maintenance process predicts work for those extra days beyond the cut-off date. This provides the maintenance department advanced visibility for maintenance work that is typically predicted in the next planning process. The maintenance department can prepare for such work in the current planning period.
2.3 Optionally, enter a Tolerance In Days to indicate a minimum interval in days that suggested Work Orders’ dates are spaced from each other.

3.1 In the Scheduling Options region, indicate how the PM Scheduler process calculates Work Order dates.
■ Start to Start: The PM Scheduler process uses the Last Service Start Date, and calculates scheduled start dates. This is a forward scheduling method.
■ Start to End: The PM Scheduler process uses the Last Service Start Date, and calculates the scheduled end dates. This is a backward scheduling method.
■ End to Start: The PM Scheduler process uses the Last Service End Date, and calculates the scheduled start dates. This is a forward scheduling method.
■ End to End: The PM Scheduler process uses the Last Service End Date, and schedules the scheduled end dates. This is a backward scheduling method.
3.2 In the Schedule Based On region, indicate how the predicted due dates are determined.
■ First Due Date: The due date is set to the first due date of all rules.
■ Last Due Date: The due date is set to the last due date of all rules.
For example, below is a Runtime Rule that includes two meters, Meter1 and Meter2.

If you specify First Due Date in the Scheduling Based On region of the PM Template, between the two meters, the first meter that hits the due reading triggers the service. In this case, if Meter1’s reading reaches the interval of 100 first, the service happens before Meter2’s reading reaches its interval of 50.
Conversely, you can choose Last Due Date in the Scheduling Based On region.
In this case, even if Meter1 reaches its due reading, the service will not be scheduled until Meter2 has also reached its due reading.
This region is disabled if the current PM schedule definition’s Scheduling Type field is populated with List Dates.

4.1 Optionally, select the Reschedule Manual Work Orders check box. If this check box is selected, unreleased manual work orders are considered during PM scheduling.

4.2 If the Run To Failure check box is selected, the Preventive Maintenance Scheduler will not automatically schedule Maintained Numbers within this Maintained Group and Activity association, however manual Work Orders can still be created. This is relevant for Maintained Numbers that cost more to maintain than the Maintained Number itself. You might also check this box for forecasting and budgeting reasons. For example, your asset is a conveyor belt. It is common in maintenance environments to let this asset wear out completely before replacing it. You estimated that the life of this asset is 18 months, and have set up a schedule for a replacement Work Order every 18 months. In reality, you found that the belts have ended up wearing out every 12 months, affecting your cost budget.

You can select this check box and clear it later. For example, you might associate a Maintained Number to an Activity, but maybe you cannot currently maintain or schedule this Maintained Number. You may have future plans to maintain this Maintained Number.

If this check box is selected, only PMs created as a copy of this PM Template will generate Work Orders for the corresponding asset in the Maintenance Workbench

4.3 Optionally, select the Default check box to indicate that the current PM schedule definition will generate Work Orders. If this check box is not selected, only Work Order suggestions are generated. You can have only one Default PM for a
Maintained Item/Activity combination.

5.1.1 For Day Interval Rules Optionally, enter Effective From and To dates to specify the rule’s expiration.

5.1.2  Enter an Interval In Days. For example, if you enter the number three, a Work Order suggestion will be created every three days. You can optionally create variable Day Interval Rules. For example, you would like Work Order suggestions created every three days in January, and every four days in February. The window below illustrates this example:

5.2.1 Optionally, within the Runtime Rules tabbed region, select a Meter Name to indicate that Preventive Maintenance scheduling is based on a Runtime Rule. If you have previously set up a Day Interval Rule, you can base the scheduling on
a Runtime Rule, as well. Only Meter Templates associated with this Maintained Group, and with the Used in Scheduling check box selected in the meter template definition, are available in the list of values.

For example, trucks of a specific Make and Model need to be scheduled for an oil change every 30 days, or every 1000 miles. If only the Runtime Rule is taken into account, the next due date will be February 10, 2002 (January 1 2002 + 40 days), and every 40 days after that. This is calculated as the interval (1000 miles) divided by the usage rate (25 miles per
The PM Scheduler process compares the above suggested dates from the runtime interval rule, to those of the day interval rule: Base Date of December 26, 2001 + every 30 days.
The Work Orders ultimately created by the PM Scheduler process are those of the earliest or latest dates, depending on how the Schedule Based On region is populated. If you selected First Due, the earliest suggestion is used for Work
Order creation. The opposite is also true.

5.2.2 The Interval and UOM fields work together. For example, for every 2000 miles, this Maintained Number needs an oil change. The UOM defaults from the Meter Template definition of the current Meter Template.
You can optionally create multiple Runtime Rules. For example, from zero to 10,000 miles, you would like your asset serviced every 3,000 miles. From 10,000 to 50,000 miles, you would like your asset serviced every 2,000 miles.

5.2.3 You cannot enter the Last Service Reading. This field is automatically updated with the meter reading information recorded at Work Order completion. Note: The Preventive Maintenance Scheduler will automatically calculate the meter usage rate, based on historical data, which is then used to predict the next meter due date. Refer to the example below.

5.3.1 If you populated List Dates within the Schedule Type field, select the List Dates tabbed region to define the specific due dates that Work Orders should transpire.
For example, you want asset, Car1, serviced on May 1 and November 1 every year for the next three years. In this case, you would create a List Dates type schedule definition, and list all the due dates within this tabbed region. The PM
Scheduler process creates suggested Work Order dates on those specified dates.

6. Save your work.

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