3.0 Preventive Maintenance

The purpose of Preventive Maintenance is to maintain the high availability of technical systems, for example production equipment & assets, in the long term. This systematic servicing of equipment to reduce the possibility of failure and downtime. It improves upon your ROI and helps in maximum productivity in turn delivering business growth. The system allow the setting up of these maintenance activities with:-

• regular inspections of equipment due to legal requirements, quality insurance or technical requirements
• periodic maintenance of technical objects

This can be used to:-

• store activities to be performed, in the form of maintenance task lists
• define the extent of preventive maintenance and inspection work to be performed
• define the frequency of these recurring activities with time-based and/or counter-based criteria

3.1 Task List

Maintenance Task Lists describe the sequence of individual maintenance activities which must be executed in a repair or maintenance job.

Task lists can be specific to a Piece of Equipment, to a Functional Location,  or can be generic (General Task List).

Task list are useful for repetitive jobs, they allow to easily create the work order used to carry out each individual repair/job. They are mostly used in planned maintenance, but can also be used in regular (unplanned) maintenance.

3.2 Maintenance Strategy, Item & Plan

Strategy - It defines the criteria/rules for the sequence of planned maintenance work. It contains general scheduling information, and can therefore be assigned to as many maintenance task lists (PM task lists) and maintenance plans as required. A maintenance strategy contains maintenance packages in which the following information is defined:

• • The cycle in which the individual work should be performed. For instance, every 100 operating hours, every three months, etc.)
  • Extra data which could affect scheduling

Item - A maintenance item describes which tasks should take place regularly at a technical object or a group of technical objects. Of course, you can assign as many maintenance items as you want to a maintenance plan. But it will always automatically contains at least one item. ??Service procurement’s maintenance plans and those plans, which refer to an outline agreement have only one item.??

Plan - Maintenance plans describe the dates and scope of the tasks. You can create maintenance plans for the technical objects in your company, thereby ensuring that your technical objects function optimally. You will create a maintenance plan for both functional locations and equipment.

Types Of Maintenance Plan

Maintenance Plans Classification

Single Cycle Plans:
A single cycle plan is the simplest form of maintenance plan. You create a single cycle plan and define exactly a time-based or performance-based maintenance cycle, in which you specify the interval at which the maintenance plan should be executed. It can be time based & performance based both.

Strategy Cycle Plans:
We create a strategy plan and assign a maintenance strategy in which you have defined the maintenance cycles (in the strategy maintenance packages). A maintenance strategy contains general scheduling information and can therefore be assigned to as many maintenance plans and maintenance task lists as required. For Example: A maintenance task is performed on a reference object after every 1000, 2000 & 5000 operating hours

Multiple Counter Plans:
Multiple counter plans are used in counter-based (performance-based) maintenance. This type of maintenance planning is not based on a maintenance strategy. This means that you create a multiple counter plan without a maintenance strategy.

In the multiple counter plan you create maintenance cycles and allocate counters of equipment or functional locations with different dimensions to them, for example, flight hours, number of takeoffs and landings, kilometers traveled. You can also integrate time-based cycles into the maintenance plan. However, these do not have counters. Alternatively, you can also create a multiple counter plan with a cycle set as a copy model for maintenance cycles.

Maintenance Plans Category

Maintenance plan categories are possible based on call object generated by a maintenance plan:

1. Maintenance Order
2. Maintenance Notification
3. Service Entry sheets
4. Inspection Notification

Maintenance Plans scheduling (Transaction – IP10)

We schedule a maintenance plan with which the system generates maintenance Notification/Order for the defined cycles. For each scheduling, the system calculates the due date (planned date) for a maintenance call object based on the scheduling parameters and the defined frequency like weekly, monthly, quarterly, yearly etc and generates maintenance calls. These maintenance calls can be fixed or skipped as per requirement. If the call object is selected as notification, then the maintenance order of required type can be created through the notification screen.

Deadline Monitoring (Transaction IP30)

This function will simplify the generation of maintenance call objects for plans. Start the deadline monitoring at regular intervals using an internally programmed report. The system then generates the maintenance call objects according to the cycles defined. A start date or an initial counter reading must have been entered in the scheduling parameters for the maintenance plan, or you must have already scheduled the maintenance plan once.

When you run the deadline monitoring function, the system converts all the maintenance calls, for which the call horizon has been reached, into maintenance call objects. The system also performs a complete rescheduling of the maintenance plan and ensures that maintenance calls are always available for the period which you have defined as the scheduling period.