PM Overview

Confidential – Copyright 2007Deere & CompanyWorldwide Agricultural Division

Process Review

Plant MaintenanceMaster DataOrder Creation & ProcessingPreventative MaintenanceGage Calibration


Chapters

The topics presented in this course include:– Technical Objects

• Functional Locations• Equipment

– Maintenance BOMs• Material BOMs• Equipment BOMs

– Work Centers– Document Links


Functional Location

• Functional location should represent the work team or physical location within a plant where maintenance tasks are performed.

• Functional locations are organized in a hierarchy.• Work Orders and Preventative Plans may be created for

Functional Locations (i.e. Facilities)• Equipment can be assigned to a functional location.• Functional locations use a defined naming convention

called a structure indicator. For example the structure could be:– Plant > Site > Department/Facility > Equipment Type


Functional Location

• Functional locations can be used to do cost analysis.– Maintenance costs for equipment installed at a

functional location will be rolled up to that functional location allowing cost analysis at the highest levels.

• Functional location master can contain:

• Location• Maintenance Plant• Location• Plant Section

• Organization• Company Code• Cost center• Planner Group


Creating a Functional Location – IL01

• Structure Indicator• The new functional location will inherit the values

of its superior functional location as long as the structure is the same.


Ottumwa Facilities Structure


Ottumwa Installed Equipment Structure


Ottumwa Miscellaneous Locations


Equipment – Creating of Required When:

• Preventative Maintenance or Repair type orders need to be written against it.

• Maintaining specific information for equipment:– Manufacturer/Vendor information (model, serial, etc)– Acquisition value / date etc.– Warranty

• The costs and reasons for performing maintenance needs to be monitored and reported.

• Functional location assignment history is needed


Creating Equipment


Maintenance BOMs

• BOMs are a list of the components (spare parts) making up a technical object (equipment) or an assembly (IBAU material).

• Used for Spare Parts (materials) Planning– For orders or task lists, you can identify and plan to use

spare parts that exist in the bill of material.

• The three types of Maintenance BOMs are:– Functional Location BOMs– Equipment BOMs– Material BOMs

• Parts purchased for equipment will not be automatically added to BOMs.– Maintain the BOM manually to add or delete any material.


© Deere & Company 2008

Work Centers

• Skilled trades group that carry out maintenance work• Uses of Work Centers:

– Operations within a work order specify work centers necessary for the task

– Scheduling – Work center Working times and shifts impact the work order start dates.

– Costing – Costs are calculated based from the cost center and activity type assigned to the work center.

– Capacity Planning – based on the number of people and shifts assigned to the work center.

– Linking to HR – Employees in HR can be linked to work centers.


General Create and View Plant Maintenance Work Orders

Order Creation & Processing


Creating & Viewing Maintenance Work Orders

Why do we create work orders?

Track cost and history

Improve machine reliability and uptime

Prioritization of work order backlog queue

Examples of when you might create a work order

Machine down

Request project work (Ex: new guard rail)

Replace a light


Basic steps to create an “EasyEntry” Work Order

Execute ZI_EASYENTRY

Creating Easy Entry WO

Step 1 Execute ZI_EASYENTRY

Step 2 Select Equip or FL

Step 3 Select Order Category

Step 4 Selections from 4 menus

Step 5 Add WO description; Review; Save


Select Equipment or Functional Location Creating Easy Entry WO








Step #3 – Select Order Category Creating Easy Entry WO






1. For the “Order Category” section, “Repair” is the default (can only select one)

Order Type Planned / Unplanned

##M3 Planned

##M1 Unplanned

##M3 Planned

##M6 Planned

2. Each radio button is associated with a specific order type.



Selections from 4 menus

Creating Easy Entry WO






Menu #1: Major objects for a Laser

Menu #2: Electrical control objects



Step #4 – Selections from 4 menusCreating Easy Entry WO






Menu #3: List of problem catalogs for a Laser

Menu #4: List of more detailed electrical problems

Note: Each Equipment or Functional Location can provide different menu selections through a Catalog Profile



Step #5 – Add WO description; Review; Save Creating Easy Entry WO






1. Type in work order description



Creating “EasyEntry” Work Orders – Normal Scenarios

• Used by Plant Maintenance module to represent an area, location, or process

• A piece of master data similar to an equipment master • Equipment can be associated (installed) to a Functional Location

More on a Functional Locations



It can represent a department



It can represent a building


Searching for Maintenance Work Orders

Work Order Status

REL Released Labor & Materials can be charged

PCNF Partially Confirmed Labor Charged; work remaining

CNF Finally Confirmed Labor Charged; all work complete

TECO Technically Complete Work Order is complete

CLSD Closed Work Order closed by batch job if TECO > 90 days



Execute IW39



For all open orders (status REL)

IW39 – Example #1:List of open work orders created by RACF CS70735, for the Davenport Works (DW01)


List of open work orders for equipment 114164 at the Davenport Works




IW39 – Example #2:List of open work orders for equipment 114164 at the Davenport Works


Plant Maintenance Execution

Order Processing


Plant Maintenance Execution

Work Order Types

Work Order Cycle processes and transactions

Work Order Selection

Work Performed

Charging Labor and Closing

Emergency / Breakdown Orders

Sub-Order Work Order (IW36)

Summary of using IW37


Work Order Cycle

Equipment

Functional Location

Execution

Work Order Creation Work Order SelectionProduction Work Performed

Add operation

Charge Labor & Close

IW37 IW32

Create Work Order

ZI_EASYENTRY

Find Work OrderIW37 Report Variant

Arrive on Work Order

IW37 IW41

Assign Work Order

IW37 IW32

CompletionMaintenance Request

Work Order Cycle

Repair Parts and/or Services Needed

Charge Labor / TECO

IW37 IW41 or IW42

Viewing Confirmations

IW47

Goods IssueIW37 IW41 Goods Movements

• Requisition (UnNumbered / Non-stock)

• Requisition (Numbered / Non-stock)

IW32 Components

Requisition (Services)IW32 Operations

Material or Equip BOM

IW32 Components List

Find Material

ZM_MAT_STOCK

Work Order Print / Print Preview

IW37 IW32


Work Order Cycle Work Order Selection Find Work Order

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32


IW37 – Change Operations: Selection of Order Operations

IW39 – Display PM orders: Selection of Orders

Display Change

Orders IW39 IW38

Order Oper

IW49 IW37



IW37 – Example #2: List of DW01 open CFM1 “Emergency / Breakdown” work orders for equipment 121796

35



36



Work Order Cycle Work Order Selection Arriving on Work Order

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32

37


From IW37, enter work center and plant

Select the line with your work order


REL

38


Enter SAP Personnel Number

Zero hours


Save

Back on the IW37 list, after refreshing New status of PCNF, and zero actual work hours

Note: It is the combination of status PCNF and zero actual work hours that tells us someone has arrived on the work order

Confirmation Screen


Work Order Cycle Work Order Selection Assigning Work Order

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



IW37 list of work orders, select line with your work order… Click the “Order” button

Add the SAP ID of the employee to be assigned to this work order…then Save…

Order screen



Back to the IW37 list of work order operations (after refresh)

First operation now has SAP ID 614125 assigned to it


Work Order Cycle Work Order Selection WO Print / Print Preview

We will now show how to print preview a work order, and direct it to a printer.

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



IW37 select line “Order” button “Order” screen

Menu: Order Print Order



default line selected is the 2010 lineThis will print to the printer designed for the skilled trades work center

Or use OVER to select a printer manually



Print Preview


Work Order Cycle Work Performed Adding an Operation

We will now review the process for adding another operation to a work order.

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32

DW



IW37



Enter description for the new operation

Enter long text if desired



To assign a person to each operation using their SAP HR ID, select both operations

Add the personnel number (SAP HR ID) for each operation

Navigation arrows


IW37 we do not see the new operation of 0020Filtered on work center M90-709…and E90-703 was added to oper 0020


Adding work center E90-703 to the filter


Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Work Order Cycle Work Performed Material or Equip BOM

2 recommended ways to find an indirect part.

Preferred method viewing a material or equipment BOM

Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32

52



53



Environment BOM item Material stock


Double click on the Material


55



56



To check stock, you can click the “Material Availability” button

Another way to check stock is the Storage Location field matchcode



Difference between a material BOM and an equipment BOM?

Equipment BOM Material is assigned directly to the equipment

Material BOM material is assigned to a “Construction Type”

The Construction Type is assigned to the Equipment

Equipment BOM

Material BOM


Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Find a part using transaction ZM_MAT_STOCK

Charge Labor / TECO

IW37 IW41 or IW42


IW47

Work Order Cycle Work Performed Find Material (ZM_MAT_STOCK)




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



ZM_MAT_STOCK

Material Types• ERSA - Spare Parts

• Repair parts; belts; bearings; pumps

• HIBE – Operating Supplies

• Office / cleaning supplies

• FHMI – Production Resource & Tools

• Grease; perishable tools, gages; fixtures; dies




Work Order Cycle Work Performed Goods Issue

Getting a repair part out of a crib.

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



From IW37, select WO and click on the “Individual confirmation” button



Click the Save button



SP01 to preview the pick ticket



Storage Type

Description Code

Barrel Crib BRL

Central Crib CTL

Electrical Crib ELC

300 Old Shot Blast OSB

Pipe Fitters Crib PFT

Vertical Towers VRT

Warehouse

Storage Type Bin Location

Part description

Part number

Transfer Order Number

Work Order Number




Creating a requisition for a part that does not have a material master, and is not stocked.

Work Order Cycle Work Performed Req (Unnumbered Non-Stock)

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



“N” for Non-Stock in the Item Category (IC) field






Requisition for an indirect part with a material master but is not normally stocked.

Work Order Cycle Work Performed Req (Numbered Non-Stock)

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



Note: This process can be used for a part that…

1. Has a material master and is not stocked

2. Is normally stocked, but you want to order some without touching the crib inventory

“N” for Non-Stock in the Item Category (IC) field






We will now review the process for creating a requisition for an outside contractor.

Work Order Cycle Work Performed Req (Services)

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47



• Requisition(Numbered / Non-stock)IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32



Purchase Requisition from the work order for outside services



Changing the control key to PM02 triggers the purchasing screen



79


Charge labor hours to a work order and technically complete (TECO)

Work Order Cycle Charge Labor & Close Charge Labor / TECO

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32

Charge Labor / TECO

IW37 IW41 or IW42


Work Order Cycle


IW47





IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32

80



Enter your personnel numberand hoursthen save

Charging labor to a work order

81

After refresh



Charge labor hours to a work order, immediately TECO (Technically Complete) it, and fill in the Cause catalog.

From IW37

82

Every operation on every work order must be “Finally Confirmed” upon completionThis drives the Actual End date on the work order which will be used on metrics reports.



83

Back on IW37



Work Order Cycle Charge Labor & Close Viewing Confirmations

Equipment

Functional Location

Execution


Add operation


IW37 IW32

Create Work Order

ZI_EASYENTRY



IW37 IW41

Assign Work Order

IW37 IW32


Work Order Cycle


Charge Labor / TECO

IW37 IW41 or IW42


IW47




IW32 Components




Find Material

ZM_MAT_STOCK


IW37 IW32

DW

84


Work Order Cycle Charge Labor & Close Viewing Confirmations DW

85


Malfunction start date and times were populated based on when the order was created and saved.

Emergency / Breakdown ##M1 Work Orders

##M1 Work Order

Emergency WO starts the breakdown clock IW42 to TECO the order and stop the breakdown clock

86


Emergency / Breakdown CFM1 Work Orders

After charging labor hours and completing the order (TECO)

Malfunction End date and time and duration populated form completing the order

DW

87


Creating a sub work order

Scenario #1 for creating sub order:

An emergency order (##M1) needs to be closed after the machine is up and running, but there is more work to do that should be associated with the original breakdown order.

The machine has been fixed, but before this order is closed create a sub-order for further needed work… IW36

DW


Creating a sub work order

Enter the description in the sub-order

Note: the status is Created (CRTD), click “Put in Process” to simultaneously REL and save

Scenario #1 for creating sub order:

An emergency order (CFM1) needs to be closed after the machine is up and running, but there is more work to do that should be associated with the original breakdown order.

After saving, the superior order can be completed


Preventative Maintenance

Order Processing


Preventive Maintenance - Overview

• Preventative maintenance is used to avoid breakdowns.• It is the generic term for planned inspection and

maintenance.• Within Preventative Maintenance you can plan time and

materials in advance.• There are two types of maintenance planning:

– Time Based – maintenance is performed in specific time cycles, like monthly or semi-annually.

– Performance (Usage) Based – maintenance is performed based on performance or usage readings of instruments that monitor the equipment. • For example, a vehicle should be serviced every 100 usage

hours; the usage information comes from an hour meter attached to the vehicle.


Preventative Maintenance Master Data


Maintenance Plan – Definition

• Description of the maintenance and inspection tasks to be performed on equipment or functional locations. The maintenance plans describe the dates and scope of the tasks.

• Contains the Maintenance Cycle or trigger when the maintenance must take place. The trigger can be time based or performance based.

• Maintenance plans must have at least one Maintenance Item. A Maintenance Item contains the technical object(s) and usually will be assigned a task list.


Task List – Definition

• Describes the sequence of individual maintenance activities which must be performed.

• Task lists can be used for preventive maintenance and routine work. They can also specify the required material to carry out the operation as well as the time needed to perform the work.

• A task list can be created specifically for an equipment or functional location or can be general and reused on multiple equipment and/or functional locations.– Equipment Task List– Functional Location Task List– General Task List


Measuring Points and Counters

• Measuring Point – physical or logical location where an equipment characteristic is measured.

• Counter – tools that you use to represent the wear and tear of an object, consumption, or the reduction of an object’s useful life. For example, an hour meter on a machine.

• Measuring Points use SAP characteristics to describe the attributes of measurement.– A characteristic describes what is being measured, and what the

unit of measure is (i.e. Hour Meter in Hours or Caliper Reading in Inches).

• Measurement Documents are created from Measuring Points. The results are stored in SAP and can be used to trigger maintenance.


Flow for Time Based Planning

Need to Generate PM’s for

Equipment based on Time

Does Equipment

exist in SAP?

Create Equipment

( IE01)

NoYes

Create Plan(IP41)

Create Task List(Optional)

(IA01 - EquipmentIA05 - General/Generic Task list

IA11 - Functional Location task list)


Flow for Usage Based Planning

Need to Generate PM’s for

Equipment based on Usage

Does Equipment

exist in SAP?

Create Equipment

( IE01)

No

Create Measuring

Point(IK01)

Yes

Create Measurement

Document(IK11 Single EntryIK34 Collective)

Get Annual Usage

Estimate

Get Latest Reading with

Date

Create Plan(IP41)

Create Task List(Optional)

(IA01 for EquipmentIA05 for General/Generic Task list)


Time Based Preventive Maintenance Execution

Weekly Run of

Batch Job(Auto)

Work Order Created

YesPlan

Triggered?

No Work Order

No


Time Based Preventive Maintenance Execution

How Time Based Preventative Work Orders are Scheduled– A Batch Job Runs Automatically

• Orders are Created from Batch Job– Time is used as a trigger for order creation.– The “Cycle” and ‘Call Horizon’ in the maintenance plan

is used to set the frequency and the call dates when the orders are created.

– Orders can be automatically printed to a specified printer.


Usage Based Preventive Maintenance Execution

Weekly Run of

Batch Job(Auto)

Work Order Created

Yes

Enter Latest Reading Against Equipment /

Measuring Point(IK11)

Plan Triggered?

No Work Order

No


Usage Based Preventive Maintenance Execution

How Usage Based Preventative Work Orders are Scheduled

A Batch Job Runs Automatically

Orders are Automatically Created

Measurement document readings plusMeasurement point annual usage estimates

§ The Trigger is when the estimated reading total meets or exceeds the cycle specified in the maintenance plan.

The “Cycle” in the maintenance plan is used to set the frequency.

The “Call Horizon” determines how early the order is created(default is 100% - or on time)

The SAP system creates “Call Dates” from a combination of the readings and annual estimate.

Orders can be automatically printed to a specified printer.


Plan Scheduling Maintenance

• A batch job automatically schedules the plan, but a tool is available to make changes to the schedule – transaction IP10 (Schedule Maintenance Plan).

• You can use IP10 to:– Change the date of a call– Skip a call– Manually trigger a call


Scheduling Overview

• SAP offers following scheduling overviews:– Graphical (IP19)

• Maintenance schedule• Capacity load

– As List (IP24)

• Both views can display historical call information• IP19 & IP24 can show the future order creation

dates (call dates)


Order Processing

Gage CalibrationGage Calibration OverviewMaster DataGage Calibration Processing


Gage Calibration Process Flow

QM/PM - Gage Calibration ProcessingTransactions in SAP

IP41 / IP02

Create PM Maint. Plan& Add Gage & Tasklist

To Maint. Plan(Single Cycle)

Gage Calb.REVIEW CATEGORY

QS31

CreateInspection Method

QM Master

REVIEW CATEGORY

IP10 / IP30

Batch Job Processing ...Search For Maintenance Plans Within Call Horizon ... Creates

Inspection Lots & PM Orders

Batch JobREVIEW CATEGORY

IE01

Create Equipment Master For New Gage

(with Object Type=G)

MIS GroupREVIEW CATEGORY

QE

QS21

Create (MIC) Master Inspection Characteristic

QM MasterREVIEW CATEGORY

IA01 / IA05

Equipment PM Task List Or

General PM Task List

Gage Calb.REVIEW CATEGORY

NewMaterial Master

required forgage?

QDV1

Create Sampling Procedure For Gage PM Calibration


Yes

QE53

Inspection Of Gage & Results Recorded On Characteristics

(repair If Req'd)

InspectorREVIEW CATEGORY

QA11

Auto Usage Decision - Closes Insp. Lot & PM Order

Updates Gage's Status &Plan's Calibrated Date

Batch / QEREVIEW CATEGORY

Calibrated Date updated

CRQ1

Create Quality Work Center For Gage Calibration


Gage's Status updated

ZQGAGEREP

Gage Calibration Report Next/Last Calibratied Date

Super/ Wage

REVIEW CATEGORY

PM Order

Repair The Gage & Return To Calibration Area

Inspector

REVIEW CATEGORY

ZQGAGERECSHT

Calibration Recording Sheet Gage Calibration Plan’s

Characteristic Target Value(s)Recording Sheet

InspectorREVIEW CATEGORY

MM01

Create Indirect Material Master For New Gage

MIS GroupREVIEW CATEGORY

No


Gage Calibration Overview

• Plant Maintenance Module– Manage master data– Monitor maintenance cycles– Calibrate

• Quality Management Module– Inspection characteristics– Inspection lots– Results recording– Usage decision


Calibration Planning & Processing

PMEquipment Master

(Gage)

PMMaintenance Plan

PMMaintenance Order

PMEquipment Task List

PMScheduling

QMInspection Characteristics

QMInspection Lot

QMResults

Recording

QMUsage

Decision


Master Data

Gage Equipment Master

Gage Task List

Gage Maintenance Plan


Functions of Equipment Master (IE01)

• Contains link to Material Master (PRT) via the Construction Type field.

• Used to track Equipment (Gage)• Keep record of calibration tasks• Report and evaluate calibrations over time

© Deere & Company

2008

IE01 - Create Equip Master for Gage

• Equipment number will be created by SAP system

• Valid On: Earliest date that the gage can be used

• Equipment category for

Gages is ‘G’


1) Equipment number assigned by SAP system

2) Description describes the gage function/size

3) Long Text- allows are a more complete description of gage function/size

4) Object type- Catalog entry that best describes type of gage

5) Size/dimension- enter the size range for gage

6) Start-up date- date to start plan

7) Manufacturer data- optional information that describes gage

Equipment Master General Data (IE01)


1) MaintPlant Physical Plant where gage is assigned

2) Room- Department where gage is assigned

3) Work Center- machine where the gage is located for production use

4) Sort field- Location where the gage is stored. Cabinet/Draw/Compartment, etc.

5) Plant Section – major building complex (DSS, FDRY, PEC, SPO & WAS) – Not used at JDDMW

Equipment Master Location (IE01)

5


1) Business Area- Appropriate division in Deere

2) Cost Center- Department that is responsible for Gage Calibration

3) Planning Plant- Plant responsible for the calibration of Gage

4) Planner Group- GAU Planner group that is responsible for Gage Calibration

5) Main WorkCtr- Main Work Center is area responsible for Gage Calibration

Equipment Master Organization (IE01)


1. Funct. Location-Physical location in plant.

2. TechIdenNo- Equals the legacy gage number included from Data Loads with plant prefix Z(i.e. NX01-X75010002)

3. ConstType- Link to the SAP Material Master of gage

Equipment Master Structure (IE01)


1)Task List Usage Set to 009 to make available to use on all task list types

Equipment Master PRT Data (IE01)


Equipment Numbers and Maintenance Task list (IA01)

IE01 - PMEquipment Master

(Gage)

IP41 - PMMaintenance Plan(calibration plan)

IA01 - PMEquipment Task List

(characteristics to check)

IE01- Create Equipment Master+

IA01- Create Equipment Task List+

IP41- Create PM Maintenance Plan

Gage Calibration Plan


Function of Equipment (gage calibration) Task List (IA01)

• Describes the steps (operations) for the calibration • Inspection characteristics are assigned to the

operation• Inspection method can be assigned• Inspection sampling procedure can be assigned.


Maintenance Task List Structure (IA01)

Equipment Task List Header:

• Material assignment

• Usage

• Status

• Validity

• Inspection Points Operation:

• Control Key

• Description

Inspection Characteristic:

• Inspection Method

• Sampling Procedure

Task list header

Operation

Operation

Inspection Char.

Group: 12345

Inspection Method

Sampling Procedure


Maintenance Task List Header (IA01)


Maintenance Task List Operation Overview (IA01)

• Work Ctr- Assign the QM Work Center responsible for Gage Calibration

• CTRL- Control Key; set to QM05 for Gage Calibration

• Insp Char- Use to create Inspection Characteristics (at bottom of screen)


Maintenance Task List Characteristic Overview (IA01)

Quantitative Inspection Characteristic

Qualitative Inspection Characteristic


Inspection Characteristics (IA01)

• What do you inspect?• Describe Inspection criteria• Used for Planning Inspections • Store Inspection specifications• May be Qualitative (pass/fail) or

Quantitative


Characteristic Overview (IA01)

Inspection characteristic on a Task List, select the Pre-set Indicator for the type of inspection characteristic.- Quantitative = D020

- Qualitative = D010

Setting preset indicator sets defaults in the Control Indicator screens for the characteristic. These can be changed if necessary.


Control Indicators – Quantitative (IA01)

The inspection characteristic Preset-indicator type (Quantitative or Qualitative) determines what information is displayed.


Control Indicators – Qualitative (IA01)

The inspection characteristic Preset-indicator type (Quantitative or Qualitative) determines what information is displayed.


Quantitative Inspection Characteristic (IA01)

• Define Upper/Lower & Target specifications• Assign sampling procedure• SPC characteristic• Summarized or single results recording• Required/Optional• Assign test equipment• Track changes


Quantitative Data (IA01)


Sample & SPC (IA01)

The Control indicator for SPC was set, the Sample tab will require selection of SPC criterion. For gage calibrations, choose: 410 - Task list char./equipment, funct.loctn.


Gage Calibration Maintenance Plan

• Calibration Cycle Frequency• Start Date• Call Horizon• Gages to be Planned• Task list for Gage assigned to Plan


Maintenance Plan (IP41)

• Cycle text = describe the cycle e.g. Annual calibration Dec (calibration is planned once/year in December)

• Cycle = a number

• Unit = period In the example, calibrations are 1/yr

• Equipment: the Gage that will be assigned to this Calibration plan

When you add the equipment, information from the equipment master is brought into the screen. Plant, Work center, planner group

• Priority: A value must be selected to help define which gage(s) should be calibrated first

• Order type: MUST be AGM5 and MaintActivityType MUST be M19

• Task List: Select Task List with binocular icon


Gage Calibration Processing

Call for Gage CalibrationRecord Calibration Results

Reporting

Gage Usage Decision


Calibration Process

• Batch job Scheduled to run weekly• Generate PM Order and Inspection Lot for each

Gage due for calibration• Calibration checked and results recorded• Usage Decision Made


Gage Calibration due

Inspection Lot

• An inspection lot is a request to a plant to carry out a quality inspection, in this case Calibration check on a Gage

• An inspection lot is created for a Gage, plant and inspection lot origin (source)

• Inspection lots are created automatically in the John Deere system

• The creation of Calibration inspection lots are triggered by release of a Gage Calibration Maintenance order

Quality InspectionEvent


Scenario – Suspect Gage Out of Calibration

• Run Report of Last/Next Calibration dates• Create a Call for Calibration manually


/DEEREAG/QMGAGEREP


Manual Call for Calibration (IP10)

• Is an Exception process• Used to Call for a Gage to be calibrated outside

of planExamples:– Dropped the Gage– Gage not repeating– Indicator is sticking

• Will be used in class to begin the Calibration cycle


Scheduling a Manual Call of Gage (IP10)

Date will automatically be entered when the

Manual Call is selectedManual Call of Gage will be created when the transaction is SAVED


Calibration Schedule proposed (IP10)

• The Calibration schedule is initially proposed. Nothing will happen until the plan is saved.

• When saved: A Maintenance Order will be created and released. (The Equipment Task list will be copied to the maintenance order.)

• When the PM Order is released, an Inspection Lot is created. Reminder: an Inspection Lot is a request to inspect something.


Results Recording – Quality Inspection (QE53)

The quality inspection takes place and results must be recorded for inspection characteristics.

During results recording, the user has access to histograms or control charts.


Results Recording Worklist for Gages (QE53)

The Work list for Gages is hierarchical• Expand one Gage by level or all of them.

• The 3rd level is the Gage master where you will record results

The Work list displays the PM Order number and Inspection characteristics assigned to the Equipment Task List


Results Recording: Characteristics Overview (QE53)

Results are recorded in Result Column and valuated when Entered

Specifications Column - contains the Lower & Upper limits


Usage Decision (QA11)

If the lot is accepted, the Gage can be returned to Production.

If the lot is rejected, follow-up actions can be triggered and the Gage can be scrapped or sent for repair.

A usage decision accepts or rejects the inspection lot.

Accept

Reject


Usage Decision is made by selecting a Code (Accept or Reject) from the pull down list.

Use the text field to enter the reaction plan and results if a gage fails calibration.

Usage Decision: Characteristic Overview (QA11)


Status Change for Object (QA11)

When SAVING the usage decision, a popup window will appear asking you to confirm that the Gage is “ready for use”. If you click the box marked Change, the status will be set to “Not ready for use”

Click Green Check mark to continue