Create Maintenance Plan#

Maintenance Plan.Create

Maintenance Plan.CreateTemplate

Maintenance Plan.CreateFromTemplate

Overview#

This operation is used to create a Maintenance Plan.

Setup#

No specific setup is required other than to meet the preconditions of the transaction.

Preconditions#

• The Maintenance Plan name must be unique.

Sequence of Steps#

There are several ways to create a new versioned object. Depending on the level, follow these steps to get started:

• Entity - in the landing page of this entity type in the Business Data menu or in the details page of an existing entity of the same type, select New on the top ribbon. For more information, see Creating Entity Objects.
• Revision - if you want to create a new revision, go to the New dropdown button on the top ribbon and select Revision. For more information, see Revisions.
• Version - if you want to create a version associated to an existing revision, go to the New dropdown button on the top ribbon and select Version. For more information, see Versions.

Step 1: Change Set#

1. Choose an existing Change Set or select Create to create a new Change Set. If configured to support implicit Change Sets, it is also possible to check the Use Automatic Change Set option.
2. Optionally, select an Approval Role.
3. Optionally, set the Make Change Set Items Effective on Approval to true so that the Change Set items become effective when the Change Set is approved.

Step 2: General Data#

1. Provide a Name for the Maintenance Plan.

2. If you are creating a new version, the revision that was selected when you started the process will be the revision to which this version will be associated. If you are creating a new entity or revision (with a new version associated to it), provide a name for the revision or it will be automatically generated for you. For more information on revision naming, see Revisions.

3. Optionally, enter a Description.

4. Select the Maintenance Plan Type. The list of possible values is taken from the MaintenancePlanType Lookup Table.

5. Select the Scope for the Maintenance Plan:

   • Maintenance Management (default)
   • In-Process Verification

6. Select Create to complete the operation and the new Maintenance Plan will be created:

   

At this point the Maintenance Plan is created but there are no Maintenance Activities defined for it. New activities can be added and existing ones can be removed by selecting the or button. Optionally, you can choose to copy activities from another Maintenance Plans:

Step 3: Adding Maintenance Activities#

To create additional activities, start with the button on the top ribbon or in the center of the window. This will show a panel on the left side where you can add the required Maintenance Activities. The details for each activity are listed on the right side panel, under several different tabs:

General Data tab#

1. Enter the Name.
2. Enter the Description.
3. Select the Type.

4. Specify the Schedule Type, which can be:

   • Ad hoc
   • Time Based
   • Usage And Time Based
   • Usage Based

   Info

   Time Based, Usage Based, and Usage And Time Based are scheduled automatically by the system and cannot be terminated manually by the user.

5. Specify the expected activity duration in hours.

6. Specify the Execution Role for this activity - this represents the group of people who is authorized/qualified to perform the maintenance task.
7. For activities of type Ad hoc it is possible to define a Request Role. If defined, only users that belong to this role are able to request this maintenance activity.
8. For activities of type Ad hoc it is possible to define a lookup table as Root Cause Source that you must specify when closing the Ad hoc Maintenance Activity Order.
9. Specify whether the approval mode is automatic or manual.

10. Define the Maintenance Type, which can be:

    • Calibration
    • Corrective
    • Inspection
    • Preventive

    Info

    The Corrective option for Maintenance Type is only available if the Schedule Type is Ad hoc.

    Note

    If when creating the Maintenance Plan the selected Scope is In-Process Verification, the Maintenance Type property will be set to this Scope and cannot be changed.

11. Choose the Material Type Restriction Mode, which defines if it is still possible to track-in a Material when the Resource is down or on hold for Maintenance (only applicable to Resources of Processing Type equal to Process or Line), which can be:

    • Allow All
    • Allow None
    • Allow Specific - you must specify the allowed Material Type (retrieved from the MaterialType Lookup Table)

    Info

    If when creating the Maintenance Plan the selected Scope is InProcessVerification, the Material Type Restriction Mode property will be set to Allow All and cannot be changed.

12. Specify whether the Maintenance Activity Order release mode is automatic or manual.

13. Specify whether the acceptance mode is automatic or manual.
14. For activities of type Time Based, Usage And Time Based, and Usage Based, it is possible to define the Auto Disable After Late Due property. So the entity with which the Maintenance Plan is associated will be put on hold if the value for Late Due is reached while the Maintenance Activity Order is yet to be performed.

15. If the activity type is Ad hoc, specify whether multiple concurrent instances of the same Ad hoc are allowed for the same Maintenance Plan Instance. If the activity type is Time and/or Usage based, specify whether the Resource (or Container) will automatically be placed on hold if the activity reaches its late due. Putting the entity on hold has the following effects:

    • For Resources, it will not be possible to track-in Materials to the Resource.
    • For Containers, it will not be possible to associate Materials with the Container.

16. Specify whether the activity must be ignored for Scheduling purposes (more specifically if the Resource must be considered available for Scheduling for the duration of the maintenance).

    Note

    If when creating the Maintenance Plan the selected Scope is InProcessVerification, the Ignore in Scheduling option is set to true and cannot be changed.

Schedule tab (for non-Ad hoc activities)#

Time Based / Usage And Time Based

1. Time due frequency scale:

   • Days
   • Hours
   • Months
   • On Shift Change - provides a way to schedule the Maintenance Activity Order based on the shift of a predetermined Calendar
   • Weeks

2. If On Shift Change, you must define the Offset Type:

   • None (default) - no offset is applied to the next shift change.
   • Duration - can define a value between 0 and 100, which is presented as a percentage and is based on the duration of the shift, if defined the Maintenance Activity Order will be scheduled to the next shift start date plus the defined duration.
   • Hours - can define a value between -24 and 24 hours (0.5 indicates 30 minutes), if defined the Maintenance Activity Order will be scheduled to the next shift start date plus the defined hours.

   

3. The recurrence details - depending on the time due frequency scale it can define days of the month, day of the week, hour of the day or simply hours. In same cases (Monthly and Weekly or Daily) it's possible also to define the time when the maintenance should be performed.

4. The early due and late due deltas - depending on the time due frequency scale it can specify days or hours depending on the time due frequency.

Usage Based / Usage And Time Based

1. Early due - in units
2. Due - in units
3. Late due - in units

4. Counter type, which can be:

   • CountExpression - use a flexible expression to increase the counter. In this case it's necessary to provide a valid Usage Based Expression (example: $Resource.IncreaseAmount or $Material.Product.ExposureIntensity)
   • CountOne - always increment the counter by one
   • CountQuantityOne - increment the counter by the primary quantity
   • CountQuantityTwo - increment the counter by the secondary quantity

   Info

   For more information, syntax and available options to create custom expressions, see Expression Evaluator.

5. Counter event, from a pre-defined list of events:

Time Based / Usage And Time Based

1. Schedule mode - which defines the day when the maintenance will be scheduled, and that can be:

   • AnyDay
   • NextWorkingDay
   • PreviousWorkingDay

   Info

   When using NextWorkingDay or PreviousWorkingDay it's necessary to have Calendar Days generated for the appropriate object.

2. Schedule next mode - which defines if the re-scheduling is fixed or dependent on when the activity is being re-scheduled, and that can be:

   • Dependant, the counter and schedule are reset once the MAO is completed.

   • Fixed, the counter and schedule are resumed once the MAO is completed. The configuration setting /Cmf/System/Configuration/MaintenanceManagement/UsageFixedNextMode/ controls the counter and targets behavior for usage based activities:

   • If not defined, the counters are adjusted and the targets remain fixed.

   • If defined as ResetCounters, the counters are reset to zero and the targets are adjusted.

3. For time based activities for which the schedule next mode is fixed, it's possible to specify a certain number of occurrences to schedule:

For more information, see Maintenance Schedule Options.

Execution tab#

This tab defines the main execution parameters.

1. Specify whether the begin and complete mode is automatic or manual. When the begin and complete mode is automatic, it's not necessary to perform the Begin and Close Maintenance Activity Order operations, only the Perform Maintenance Activity Order.
2. Optionally define a Checklist (must be of scope Maintenance Management) to be performed as part of the normal maintenance. If the begin and complete mode is manual, it's necessary to specify a Checklist to be performed.
3. Optionally define a Data Collection to be performed as part of the normal maintenance.
4. Optionally define a Data Collection Limit Set to be applied as part of the normal maintenance.
5. Optionally define a Checklist (must be of scope Maintenance Management) to be performed as part of rework.
6. Optionally define a Data Collection to be performed as part of rework.
7. Optionally define a Data Collection Limit Set to be applied as part of rework.

8. If a Data Collection is defined for either normal or rework maintenance, it's possible to define a list of Charts for which data will be sent. The same integration principles as defined for Integrating EDC with SPC apply. For SPC Chart visualization there are the following different possible modes:

   • AcknowledgeAlways - the Chart is always displayed and must be acknowledged by the user.
   • AcknowledgeOnViolationsOnly - the Chart is only displayed in case that there is a violation and must be acknowledged by the user.
   • DisplayAlways - the Chart is always displayed and but does need to be acknowledged by the user.
   • DisplayOnViolationsOnly - the Chart is only displayed in case that there is a violation but does need to be be acknowledged by the user.
   • None - the Chart is never displayed.

Parts tab#

The parts tab defines the bill of parts, expressed as a Bill-of-Materials (BOM), for the maintenance task. It's necessary to define:

1. Whether the maintenance activity can only use parts from the BOM or if the user can add additional parts.
2. Define the BOM of scope Parts to be used to as the bill of parts.
3. The Part Designator (optional).

Personnel tab#

The Personnel tab defines the labor requirements for the Maintenance Activity.

1. Select Enable Check-In to enable Employees to check-in into the MAO.
2. Select Is Restricted to only allow Employees with one of the required Certifications to check-in into the MAO.
3. Select Enforce personnel requirements at perform to only allow Perform MAO to take place if all Personnel Requirements are met.
4. Select Automatically check-in employee on begin to automatically check-in the current Employee when the MAO is begun.
5. Select Require check-in for perform to prevent Employees which are not checked-in from Performing the MAO.
6. Select Employee can check-out others on check-in to allow Employees to replace other Employees when checking-in.
7. Select Log check-in activity, to add entries automatically to the Employee Timesheet.
8. Select Allow manual report to allow manual labor hours to be reported for the MAO.

Specific personnel requirements can be configured by selecting the Manage button in each of the Personnel Requirements section.

After opening the Manage Activity Personnel Requirements wizard, you can add or remove rules by selecting the or buttons and selecting the appropriate values for:

• Certification - the required certification.
• Quantity - the quantity required for that certification.
• Allocation - the allocation for the certification, ranging between (and including):
  • 0 (no allocation)
  • 1 (100% allocation)
• Exclusive - whether the user can only be checked-in at this maintenance activity.

The difference between Allocation and Quantity can be understood through the following example. In order to have one (1) Employee associated to the Maintenance Activity, possible configurations can be:

Table: Allocation and Quantity configurations for Maintenance Activity Personnel Requirements

Documents tab#

The Documents tab allows you to include Documents that can be consulted when a MAO is being executed, using a drag-and-drop interface.

Rules tab#

The rules tab defines actions which are triggered when the MAO schedule state reaches a particular schedule state.

1. For Time Based and Usage And Time Based activities, the following states can have rules associated by selecting the Manage button in each of the schedule state sections:

   • Time early due
   • Time due
   • Time late due

2. For Usage Based and Usage And Time Based activities, the following states can have rules associated by selecting the Manage button in each of the schedule state sections:

   • Usage early due
   • Usage due
   • Usage late due

After opening the Manage Activity Rules wizard, you can add or remove rules by selecting the or buttons and selecting the appropriate rules:

Contains tab#

This tab is used to define inclusion relationships for the Maintenance Activity. For example, if a Yearly Maintenance Activity includes a Monthly Maintenance Activity, it's possible to establish this relationship and have the system link them together automatically during runtime. There are some rules for inclusion:

• The Maintenance Activities must have the same Schedule Type and must not be Ad hoc.
• Both the parent and included Maintenance Activities must be in the same Maintenance Plan version.
• The included Maintenance Activity must have a shorter cycle than the parent Maintenance Activity.
• There cannot be circular references.
• Each Maintenance Activity can only have one top-most Maintenance Activity. For example: A includes B and B includes C is valid whereas A includes B and D includes B is invalid.
• Furthermore, to allow inclusion of one Maintenance Activity in another, the following properties must be identical:
  • Material Type Restriction Mode
  • Material Type
  • Required Material Product
  • Required Material Flow
  • Required Material Flow Path
  • Required Material Logical Flow Path
  • Required Material Step
  • Qualification Service
  • Post Maintenance Activity Qualification
  • Requires Evaluation
  • Material Evaluation Flow
  • Material Evaluation Flow Path
  • Material Evaluation Logical Path
  • Material Evaluation Step
  • Material Evaluation Results Capture Mode

1. Add or remove as many Maintenance Activities as desired selecting the option Join Automatically if it's intended that the system joins the two MAOs automatically whenever there's an overlap in the schedule (given by the early due - late due interval):

   

   Info

   It's always possible to join and separate the MAOs later manually.