MRO MAINTENANCE

 

The MRO Maintenance application supports Maintenance Process Management as shown in the following picture:

The maintenance process steps are detailed below:

• maintenance request creation and its printout

• request to approval (communication via email)

• maintenance order automatic creation after request approval

• spare parts, tools and check list assignment to maintenance order

• scheduling execution dates with planned duration

• maintenance order printout

• maintenance order confirmation (starting of maintenance job) with actual start date setting and maintenance planned cost automatic calculation based on spare parts costs, tool hourly rate and assigned personnel cost rate

• execution of maintenance job checking material availability and reserving tools

• maintenance order closing by releasing tools, automatic request closing, communication via email to the requestor, actual cost calculation and analytic account posting by nature (material, tool and labor) for comparing actual figures with budged ones

 

The maintenance request is useful for requesting maintenance job especially for the corrective, inspection and retrofit maintenance strategies.

Maintenance orders can be created manually without any maintenance request as reference or automatically as result of maintenance procedures run (on condition, periondic and maintenance plan)

 

Main features:

•          The following maintenance strategies have been implemented:

o   Corrective

o   Preventive

o   On condition

o   Periodic

o   Maintenance Plan

o   Inspection

o   Retrofit

•          communication via email to the requester for the following events: approval request, maintenance order closing and maintenance request rejection in maintenance order

•          maintenance team management and technician assignment as team members

•          dashboard for supporting maintenance teams in their daily activities

•          odoo activity views have been activated for the most of the maintenance objects

•          logical archiving feature

•          equipment assignment to user (integration with HR module)

•          equipment hierarchy for collecting maintenance costs to upper level

•          functional location management where an equipment is installed or temporary stored,

•          equipment classification through equipment categories for automatic task determination on periodic and on condition maintenance strategies

•          tool management with availability check and calibration date management

•          spare parts availability checking and automatic consumption (integration with inventory module)

•          spare parts consumption account setting for specific virtual location (integration with stock account module)

•          check list management and its breakdown in activities

•          maintenance task management per maintenance policies for collecting spare parts, tools and check list

•          priority assignment in maintenance request as: low, normal, high and breakdown (very high)

•          wizard for converting maintenance order in task

•          accounting integration with actual costs calculation and analytic account posting by nature (material, tool and labor) for comparing actual figures with budged ones

•          specific analytic account assignment for retrofit and inspection maintenance strategies: it is possible to enter an analytic account in retrofit and inspection maintenance requests for collecting all maintenance costs

•          maintenance order scheduling is calculated based on working calendar assigned to maintenance team

•          on condition maintenance process with automatic maintenance order creation based on measures managed through gauges and points of measures

•          gauge management and its measures

•          gauge assignment and its installation to a single equipment

•          periodic maintenance process with automatic maintenance order creation based on cumulated measures in meters or working time spent from the last maintenance order

•          meter management and its measures

•          meter assignment and its installation to a single equipment

•          maintenance plan process as maintenance strategy with automatic maintenance order creation based on measures managed through meters and points of measures compared with planned utilizations and planned maintenance dates listed in a maintenance plan

•          It is possible to run maintenance strategies (on condition, periodic and maintenance plan) selecting specific equipments only.

•          reports for:

o   equipment cost analysis (actual costs)

o   equipment hierarchy cost analysis (cumulated actual costs: Actual Material Cost Cumulate, Actual Tool Cost Cumulate and Actual Labour Cost Cumulate)

o   maintenance cost analysis (actual costs)

o   tool utilization analysis (actual tool utilization for calibration date management)

 

 

On condition maintenance procedure:

On condition maintenance is based on actual measures provided by a gauge installed to an equipment. A maintenance order is automatically created whether a measure is out of the allowed interval. Therefore, we have as follows:

•          the process is triggered for “not processed” measures outside the allowed interval/thresholds for gauge assigned and installed to an equipment

•          an active maintenance order does not exist

•          a new on condition maintenance order is created

•          all not processed measured are set as processed

•          the reference to the new maintenance order is recorder on the related measure for tracking purposes

 

 

Periodic maintenance procedure:

Periodic maintenance is based on actual equipment utilization provided by a meter installed to an equipment. A maintenance order is automatically created whether cumulated utilization or working time spent from the last maintenance order exceeded defined threshold. Therefore, we have as follows:

•          the process is triggered based on the following two conditions:

o   the actual time calculated from the last periodic maintenance order (if none, meter installment date) is upper than a threshold

o   the actual utilization calculated as actual measure – “utilization from the last periodic maintenance order” is upper than a threshold

•          the related meter has to be “operative” and assigned to an equipment

•          an active maintenance order does not exist

•          a new periodic maintenance order is created

•          the reference to the new maintenance order is recorder on the related measure for tracking purposes

 

 

Maintenance Plan procedure:

The Maintenance Plan defines a list of planned maintenance jobs for a specific equipment. A plan maintenance item is described by a planned date, a planned utilization and a maintenance task. A dedicated meter has to be assigned to an equipment subjected to maintenance plan. Based on actual utilization and or current date compared with planned utilization and planned date a maintenance order with maintenance plan as maintenance strategy is created. Therefore, we have as follows:

•          the process is triggered when one of the following two conditions occurs for a maintenance plan item:

o   the planned date is in the past

o   the actual utilization calculated as actual is upper than the planned utilization

•          the related meter has to be “operative” and assigned to an equipment

•          an active maintenance order does not exist

•          a maintenance plan order is created

•          the reference to the new maintenance order is recorder on the related maintenance plan item for tracking purposes

•          after processing the maintenance plan order, its reference is reported on the related maintenance plan item for tracking purposes and the maintenance item is closed

•          Maintenance plan procedure can be performed manually by created maintenance order manually and reporting it on the corresponding maintenance plan item.

 

 

Maintenance Configuration

 

MAINTENANCE TEAM

•          integration with equipment master data

•          company assignment for activating all security checks

•          entering team members: a member can belong to several maintenance teams

•          hourly cost rate for planned and actual labor cost evaluation in maintenance order processing

•          analytic account for analytic posting at maintenance order closing

•          working calendar assignment for time scheduling in maintenance order processing

•          Kanban and activity views

•          logical archiving features

•          document attachment management

 

 

FUNCTIONAL LOCATION

•          functional location hierarchy, i.e. hierarchical representation of places/machines where an equipment is installed

•          equipment master data integration: equipment state changing in maintenance order processing based on its functional location

•          only one scrap location has to be set up (system check) where a scrapped equipment is logically stored

•          integration with maintenance order processing to forbid maintenance order creation for a scrapped equipment

•          only one warehouse location has to be set up (system check) where not installed equipment are temporary stored

•          system check to have the scrap location different to the warehouse one

•          logical archiving feature

 

 

EQUIPMENT CATEGORY

•          equipment classification

•          equipment master data integration

•          logical archiving feature

 

 

Maintenance Master Data

 

TOOL MASTER DATA

•          check unique tool creation based on tool name and tool code

•          hourly cost rate for planned and actual tool usage cost evaluation and analytic posting at maintenance order closing

•          tool availability check and maintenance order integration: check a tool can be used to an only one maintenance order

•          calibration date management: a maintenance order cannot be confirmed if one of allocated tools has an expired “next calibration date” (next calibration date is compared to the scheduling start date)

•          Kanban and activity views

•          logical archiving features

•          document attachment management

 

 

CHECK LISTS (MAINTENANCE ACTIVITIES)

•          list of activities to be performed in a maintenance order

•          Kanban and activity views

•          logical archiving features

•          document attachment management

 

 

SPARE PARTS (PRODUCT MASTER DATA)

•          specific indicator for selecting products used in maintenance

 

 

MAINTENANCE TASKS

•          Maintenance task is for collecting spare parts, tools, planned duration and check lists to be suggested as default in a maintenance order

•          A task for each maintenance strategy has to be entered at equipment level

•          Task can be selected in a maintenance order based on its equipment category

•          Kanban and activity views

•          logical archiving features

•          document attachment management for operative instruction management: instruction documents allocated to a task are imported automatically to maintenance order

 

 

GAUGE MASTER DATA

•          gauge thresholds have to be assigned for defining interval of allowed measures: a measure out of the allowed interval is the starting point for on condition maintenance process

•          gauge UoM for thresholds

•          two states are managed: setup and operative (installed to an equipment)

•          only one equipment can be linked (system check) to a gauge

•          Kanban and activity views

•          logical archiving features

•          document attachment management

 

METER MASTER DATA

•          two states are managed: setup and operative (installed to an equipment)

•          mater UoM for utilization to be entered as meter measure

•          only one equipment can be linked (system check)

•          two kind of “measure type” are available for meters:

o   progressive: the actual utilization is the value of the last measure

o   delta: the actual utilization is the sum of all measures

•          actual utilization and last measure date calculated from measures

•          Kanban and activity views

•          logical archiving features

•          document attachment management

 

 

EQUIPMENTS

•          Functional location management

•          Equipment status management with the possible following values:

o   Warehouse,

o   Breakdown,

o   in Maintenance (maintenance order running),

o   Operative (installed) and

o   Scrapped (no maintenance order creation)

•          The equipment status is automatically determined based on functional location and maintenance orders in progress

•          check unique equipment creation based on name and code

•          check to forbid maintenance order confirmation for scrapped equipment

•          Criticality assignment: general, important, very important and critical

•          warranty details with manufacturer, warranty period and vendor

•          integration with HR employee master data (equipment assigned to a user)

•          the next maintenance date determination as end scheduled date for the next maintenance order in progress: in the kanban view, the next maintenance date in the past is pointed out in red

•          link to maintenance requests created for this equipment

•          link to maintenance orders created for this equipment

•          Kanban and activity views

•          logical archiving features

•          document attachment management

 

on condition maintenance page:

•          wizard to assign a gauge to an equipment and the related maintenance task (only gauges not yet assigned are listed)

•          wizard to unassign gauge to an equipment (check only detached gauges can be unassigned)

•          wizard for entering measures related to the assigned gauge

 

periodic maintenance page:

•          wizard to assign a meter to an equipment with its parameters: threshold time, threshold utilization, maintenance task, working calendar (only meters not yet assigned to another equipment are listed)

•          wizard to unassign meter to an equipment (check only detached meters can be unassigned)

•          wizard for entering measures related to the assigned meter

 

hierarchy page:

•          hierarchical representation of a complex equipment

•          subequipment counting of all assigned equipments in all hierarchical level

•          check parent equipment has to be active

•          check no recursive assignment

•          maintenance equipment cost calculation for a single equipment

•          maintenance cost calculation based on hierarchical equipment structure

 

Kanban view:

 

Maintenance Process

 

DASHBOARD

•          dashboard for supporting maintenance teams in their daily activities: list of running maintenance order (not in state cancel or done) detailing them in released, ready for maintenance (spare parts available) and late

•          calendar view is provided for open maintenance orders assigned to a maintenance team

 

 

MAINTENANCE REQUEST

•          state management with the possible following values:

o   Draft à initial creation state

o   Confirmed à requester approval performed

o   Execution à maintenance order running

o   Done à maintenance order closed

o   Rejected à maintenance request rejected

o   Cancelled à maintenance request cancelled

•          Process steps:

o   The maintenance request is created by entering the following data:

§  Equipment

§  Request date

§  Maintenance type

§  Requester

§  Cause (detailed description of maintenance request, reported in the related maintenance order)

o   After saving, the creator sends a mail to the requester for maintenance request approval

o   the requestor can approve it and a maintenance order with reference to this request is automatically created

o   or reject it detailing the rejection reason, reported into the related maintenance request

o   the maintenance order confirmation moves the maintenance request state in execution

o   after performing the maintenance job, so closing the maintenance order, the maintenance request will be automatically closed (state done)

•          possible maintenance types are:

o   Corrective

o   Inspection

o   Retrofit

•          priority state as low, normal, high, breakdown (very high)

•          in breakdown priority, the requested date is automatically set as the today’s date.

•          Priority is reported in the maintenance order and it is checked that in breakdown the corrective maintenance type is the only possible maintenance strategy

•          maintenance request printout

•          activity views

•          calendar view for open maintenance requests

•          logical archiving features

•          document attachment management

 

 

MAINTENANCE ORDER

•          state management with the possible following values:

o   Draft à initial creation state

o   Released à order approved with waiting parts

o   Ready à order approved with available parts

o   Done à maintenance order closed

o   Cancelled à maintenance order cancelled/rejected

•          Process steps:

o   A maintenance order is created manually or automatically by approving a request

o   maintenance request is reported into the related maintenance order

o   scheduling by entering the end schedule date and the planned duration (backward scheduling)

o   maintenance manager can approve or reject maintenance order

o   a maintenance order cannot be confirmed without entering a maintenance team and selecting only one check list

o   in case order rejection, a mail is sent out to the maintenance requester

o   spare parts, tools, planned duration and check lists are suggested by default by selecting the proper task

o   the maintenance type and the requested date are reported from the maintenance request and it is not possible to change them

o   at confirmation the planned costs are automatically calculated and actual start execution date is set

o   the closing sets the end execution date, calculate the actual costing figures and performing analytic posting; a mail is sent out to the requestor to inform him/her the maintenance job has been performed

•          possible maintenance types are:

o   Corrective

o   Preventive

o   On condition

o   Periodic

o   Inspection

o   Retrofit

•          analytic postings on analytic account set in maintenance team master data for spare parts costs, labor costs and tools utilization costs

•          maintenance order printout (with all needed information for performing it) activity views

•          Kanban and activity views

•          calendar view for open maintenance orders

•          logical archiving features

•          document attachment management for operative instructions and general documents

 

 

POINTS OF MEASURE (GAUGES) for on condition maintenance

•          measures related to a gauge can be entered

•          measure can be entered for installed gauges and assigned to an equipment only (system checks)

•          the measure date has to be after the “installment date” (system check)

•          measure processed indicator is automatically set for each measure processed in on condition planning run

•          planning results are reported for each processed measure with the reference of the Maintenance order created

 

 

METER MEASURES for periodic maintenance

•          measures related to a meter can be entered

•          measure can be entered for installed meters and assigned to an equipment only (system checks)

•          the measure date has to be after the “installment date” (system check) and after the last measure date (only progressive measure sequence is allowed)

•          check for positive measure only are allowed

•          check for progressive measure type: the measure has to be greater than the last one

•          planning result are reported for the last processed measure with the new Maintenance order created